Removal Procedure
- Inspect the fluid level
in the brake master cylinder reservoir.
- 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.
- 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.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Install and hand tighten a wheel lug nut in order to retain the
rotor (A4WD only).
- Compress the front caliper piston.
| • | Install a large C-clamp over the top of the caliper housing and
against the back of the outboard pad. |
| • | Slowly tighten the C-clamp until the piston pushes into the caliper
bore enough to slide the caliper off the rotor. |
| • | Remove the C-clamp from the caliper. |
Notice: Support the brake caliper with heavy mechanic wire, or equivalent,
whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and
in turn may cause a brake fluid leak.
- Remove the caliper from the mounting bracket and support the caliper
with heavy mechanics wire or equivalent. DO NOT disconnect the hydraulic brake
flexible hose from the caliper. Refer to
Brake Caliper Replacement
- Remove the inboard brake
pad (RWD only).
- Remove the retainer spring (RWD only).
- Remove the outboard brake pad (RWD only).
- Remove the inboard and
outboard brake pads (A4WD only).
- Inspect the following parts for cuts, tears, or deterioration.
Replace any damaged parts:
| • | The disc brake mounting hardware. |
- Inspect the caliper bolts for corrosion or damage. Do not attempt
to polish away any corrosion. If corrosion is found, use new parts, including
bushings, when installing the caliper.
Installation Procedure
- Using a C-clamp (1), bottom the
piston into the caliper bore. Use an old brake pad or wooden block (2)
placed across the face of the piston. Do not damage the piston or the caliper
boot.
- Install the inboard brake
pad (A4WD only).
- Install the outboard brake pad (A4WD only).
- Install the retainer spring
onto the inboard brake pad (RWD only).
- Install the inboard brake pad (RWD only).
- Install the outboard brake pad (RWD only).
- Compress the outboard
pad ears to the caliper (RWD only).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the caliper mounting bolts.
Tighten
Tighten the caliper mounting bolts to 51 N·m (38 lb ft).
- Remove the wheel lug nut securing the rotor to the hub (A4WD only).
- Install the tire and wheel. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Lower the vehicle.
- With the engine OFF, gradually apply the brake pedal aproximately
2/3 of its travel distance.
- Slowly release the brake pedal.
- Wait 15 seconds, then repeat steps 12-13 until a firm brake
pedal is obtained. This will properly seat the brake caliper pistons and brake
pads.
- Fill the brake master cylinder to the proper level. Refer to
Master Cylinder Reservoir Filling
in Hydraulic Brakes.
- Burnish the pads and rotors. Refer to
Brake Pad and Rotor Burnishing
.
