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.
- Only on the A4WD, install and hand tighten a wheel lug nut in order to retain the rotor.
- Compress the front caliper piston, with the following procedure:
- Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. Refer to Brake Caliper Replacement .
- Only on the RWD, remove the inboard brake pad .
- Only on the RWD, remove the retainer spring.
- Only on the RWD, remove the outboard brake pad.
- Only on the A4WD, remove the inboard and outboard brake pads.
- Inspect the following parts for cuts, tears, or deterioration:
- Replace any damaged parts. Refer to Disc Brake Mounting and Hardware Inspection , or to Brake Caliper Inspection .
- Inspect the caliper bolts for corrosion or damage.
| 7.1. | Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. |
| 7.2. | Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor. |
| 7.3. | 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.
Important: DO NOT disconnect the hydraulic brake flexible hose from the caliper.
| • | The disc brake mounting hardware |
| • | The caliper dust boot |
Important: 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.
- Only on the A4WD, install the inboard brake pad.
- Only on the A4WD, install the outboard brake pad.
- Only on the RWD, install the retainer spring onto the inboard brake pad.
- Only on the RWD, install the inboard brake pad.
- Only on the RWD, install the outboard brake pad.
- Only on the RWD, compress the outboard pad ears to the caliper.
- Install the caliper mounting bolts.
- Only on the A4WD, remove the wheel lug nut securing the rotor to the hub.
- 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 approximately 2/3 of the pedal's 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 .
Important: Do not damage the piston or the caliper boot.
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.
Tighten
Tighten the bolts to 51 N·m (38 lb ft).
