Brake Caliper Replacement Front

Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Mark the relationship of the wheel to the hub.
4. Remove the tires and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Install two wheel nuts to retain the rotor.



5. Push the piston (4) onto the caliper bore in order to provide clearance between the linings and the rotor. Complete the following steps:

5.1.	Install a large C-clamp over the top of the caliper housing (3) and against the back of the outboard pad (1).

5.2.	Slowly tighten the C-clamp until the piston (4) pushes into the caliper bore enough to slide the caliper (3) off the rotor. Do not overtighten the C-clamp. Overtightening the C-clamp will deform the outboard pad (1).

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

6. If you remove the caliper from the vehicle for unit repair (overhaul), then remove the brake hose bolt that attaches the inlet fitting. If only the brake pads are being replaced, do not disconnect the inlet fitting.
7. Plug the openings in the caliper housing and the pipe in order to prevent brake fluid loss and contamination.



8. Remove the caliper bolts (3).
9. Remove the caliper housing (1) from the rotor and the caliper bracket (2).
10. Inspect the bolt boots for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace the bolt boots if damage exists. Refer to Brake Caliper Bracket Replacement .

11. Inspect the piston boot for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace the piston boot in the caliper if damage exists. Refer to Brake Caliper Overhaul .

12. Inspect the bolt boots in the caliper bracket for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace the bolt boots in the caliper bracket if damage exists. Refer to Brake Caliper Bracket Replacement .




13. Inspect the caliper bolts (1) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion.

1. Install the caliper housing (1) over the rotor and the caliper bracket (2). Ensure that the bushings are in place.



2. Lubricate the caliper bolts (1). Use silicone grease. Do not lubricate the threads.



3. Lubricate the two bolt boots in the caliper bracket (6). Use silicone grease.




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.

4. Install the caliper bolts (3). Use a screwdriver in order to push the bolt boot over the shoulder of the caliper bolt. Ensure that the bolt boot fits securely in the groove of the pin bolt.

Tighten
Tighten the caliper bolts to 85 N·m (63 lb ft).

Important: Replace the copper gaskets.

5. Install the brake hose bolt, if removed.

Tighten
Tighten the brake hose bolt to 54 N·m (40 lb ft).

6. Remove the wheel nuts securing the rotor to the hub.
7. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Align the previous marks on the wheel and the hub.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
10. Bleed the caliper if the inlet fitting was removed. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
11. Apply the brake pedal approximately three times after bleeding, if necessary.
12. Inspect the hydraulic brake system for brake fluid leaks.

Brake Caliper Replacement Rear

1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Mark the relationship of the wheel to the hub and bearing.
4. Remove the tires and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Install two wheel nuts in order to retain the rotor.



5. Push the piston (7) onto the caliper bore (2) in order to provide clearance between the linings and the rotor. Complete the following steps:

•	Install a large C-clamp over the top of the caliper housing (15) and against the back of the outboard pad (9).

•	Slowly tighten the C-clamp until the piston (7) is pushed into the caliper bore (2) enough in order to slide the caliper (15) off the rotor. Do not overtighten the C-clamp. Overtightening will deform the outboard pad (9).

6. Remove the hose bolt attaching the inlet fitting.
7. Plug the openings in the caliper housing (15) and the pipe in order to prevent brake fluid loss and contamination.
8. Remove the caliper bolts (1 and 3).




Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

9. Remove the caliper housing (3) from the rotor (4) and the caliper bracket (1).
10. Inspect the piston boots for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace the piston boots if damage exists. Refer to Brake Caliper Overhaul .

11. Inspect the caliper bracket boots for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace the caliper bracket boots if damage exists. Refer to Brake Caliper Bracket Replacement .

12. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing caliper. Do not attempt to polish away corrosion.

1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are in place.



2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads.
3. Lubricate the two rubber boots (13 and 4) in the caliper bracket (12). Use silicone grease.

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.

4. Install the caliper bolts (1 and 3). Use a flat bladed tool in order to push the boot over the shoulder of the caliper bolt. Ensure that the boot is securely in the groove of the caliper bolt.

Tighten
Tighten the caliper bolts (1 and 3) to 44 N·m (32 lb ft).

Important: Replace the copper gaskets.

5. Install the brake hose bolt.

Tighten
Tighten the brake hose bolt to 54 N·m (40 lb ft).

6. Remove the wheel nuts securing the rotor to the hub and bearing.
7. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Align the previous marks on the wheel and the hub and bearing.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
10. Bleed the entire brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
11. Apply the brake pedal approximately three times after bleeding, in order to seat the pads against the rotor.
12. Inspect the hydraulic brake system for brake fluid leaks.