Brake Caliper Replacement - Front
Brake Caliper Replacement - FrontRemoval Procedure
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise the vehicle and suitably support. Refer to Vehicle Lifting.
5. Mark the relationship of wheel to the axle flange.
6. Remove the tire and wheel assembly.
7. Lift the electronic brake wear sensor retainer clip.
8. Remove the electronic brake wear sensor wire from under the retainer clip.
9. Carefully pulling up on the electronic brake wear sensor wire and with a small screw driver push the retaining clip inward and remove the electronic brake wear sensor from the inner brake pad.
10. Disconnect the electronic brake wear sensor connector.
11. Remove the electronic brake wear sensor form the caliper.
12. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
13. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
14. Remove the C-clamp from the caliper.
15. Remove the brake caliper inlet fitting bolt to the brake caliper.
16. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
17. Plug the opening in the brake caliper and brake hose to prevent fluid loss and contamination.
18. Remove the brake caliper pin bolts.
19. Remove the brake caliper.
Installation Procedure
1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent.
2. Dry the brake caliper pin bolts and retainers, using non-lubricated, filtered air.
3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts do NOT apply lubricant to the brake pad hardware.
4. Install the brake caliper over the brake pads into the brake caliper bracket.
Notice: Refer to Fastener Notice in Service Precautions.
5. Install the brake caliper pin bolts.
^ Tighten the brake caliper pin bolts to 85 Nm (63 lb ft).
Important: Install NEW copper brake hose gaskets.
6. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
7. Install the brake caliper inlet fitting bolt to the brake caliper.
^ Tighten the brake caliper inlet fitting bolt to 45 Nm (33 lb ft).
Important: Care must be taken that the electronic brake pad wear sensor harness is routed properly, to avoid damaging the harness.
8. Install the electronic brake wear sensor wiring (1) to the caliper.
9. Install the electronic brake wear sensor to the caliper.
10. Connect the electronic brake wear sensor connector.
11. Insert the electronic brake wear sensor into the inn brake pad.
12. Lift the electronic brake wear sensor retainer clip and install the wire under the clip.
13. Bleed the brake system.
14. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
15. Slowly release the brake pedal.
16. Wait 15 seconds, then repeat steps 14-15 until a firm brake pedal apply is obtained, This will properly seat the brake caliper pistons and brake pads.
17. Install the tire and wheel assembly.
18. Lower the vehicle.