Front Brake Caliper Replacement 1500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

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 and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.



6. Compress the brake caliper pistons.

6.1.	Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad.

6.2.	Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores.

6.3.	Remove the C-clamps from the caliper.




7. Clean all dirt and foreign material from the brake caliper.

Note: Cap or plug the brake hose to prevent brake fluid loss and contamination.

8. Remove the brake hose to caliper bolt.

Note: Ensure the washers are not still attached to the brake hose or the brake caliper.

9. Remove and discard the 2 copper brake hose gaskets.
10. Remove the brake hose from the brake caliper.




Note: 

•	DO NOT use any air tools to remove or install the brake caliper bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the brake caliper bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

11. Using an open end wrench to hold the guide pin, loosen the brake caliper bolts.



12. Remove the brake caliper bolts.



13. Remove the brake caliper from the mounting bracket.

1. Install the caliper to the caliper bracket.



2. Install the brake caliper bolts.

Caution: Refer to Fastener Caution in the Preface section.





Note: 

•	DO NOT use any air tools to remove or install the brake caliper bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the brake caliper bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

3. Using an open end wrench to hold the guide pins while tightening the brake caliper bolts to 100 N·m (74 lb ft).
4. Remove the cap or plug from the brake hose fitting end.



5. Install the brake hose to caliper bolt and tighten to 40 N·m (30 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.

Front Brake Caliper Replacement 2500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

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 and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.



6. Compress the brake caliper pistons.

6.1.	Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad.

6.2.	Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores.

6.3.	Remove the C-clamps from the caliper.

7. Clean all dirt and debris from the brake caliper and fittings.




Note: 

•	Cap or plug the brake hose to prevent brake fluid leakage and contamination of the brake system.

•	Ensure that the washers are not still attached to the brake hose or the brake caliper.

•	DO NOT re-use the washers, discard and replace with new.

8. Remove the brake hose to caliper bolt.
9. Remove the brake hose from the brake caliper.
10. Remove and discard the 2 copper brake hose gaskets.




Warning: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

11. Remove the brake caliper guide pin bolts from the brake caliper.
12. Remove the brake caliper from the caliper mounting bracket.

1. Install the brake caliper to the caliper mounting bracket.

Caution: Refer to Fastener Caution in the Preface section.




2. Install brake caliper guide pin bolts and tighten to 108 N·m (80 lb ft).
3. Remove the cap or plug from the brake hose to caliper fitting.

Note: Install 2 NEW copper brake hose gaskets.

4. Assemble the 2 copper brake hose gaskets to the brake to caliper bolt and the brake hose.



5. Install the brake hose to caliper bolt and tighten to 45 N·m (33 lb ft).
6. Bleed the brake system. Refer to Hydraulic Brake System Bleeding.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.