Caliper Assembly

WARNING: 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.

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

Caliper Front (Cutaway View):

REMOVE OR DISCONNECT
1. Two-thirds of the brake fluid from master cylinder.
2. Raise vehicle and suitably support.
3. Mark relationship of wheel to hub.
4. Tires and wheels.

NOTE: Install two wheel nuts to retain rotor.

5. Push piston onto caliper bore to provide clearance between linings and rotor.
a. Install a large C-clamp over top of caliper housing and against back of outboard pad.
b. Slowly tighten C-clamp until piston is pushed into the caliper bore enough to slide the caliper off rotor.

NOTE: If C-clamp is tightened too far, the outboard pad will be deformed and require replacement.

6. Brake hose bolt attaching inlet fitting only if caliper is to be removed from vehicle for unit repair (overhaul). If only brake pads are being replaced, there is no need to disconnect inlet fitting.

NOTE: Plug openings in caliper housing and brake hose to prevent brake fluid loss and contamination.

Caliper Attachment:

Caliper Mounting Bolt:

Suspending Caliper:

7. Caliper bolts.
8. Caliper housing from rotor and caliper bracket.


INSTALL OR CONNECT
1. Caliper housing over rotor and caliper bracket.

NOTE: Make sure bushings are in place.

2. Lubricate caliper bolts using silicone grease.

CAUTION: Do not lubricate threads.

3. Lubricate two bolt boots in caliper bracket using silicone grease.
4. Caliper bolts and tighten to 85 Nm (63 ft. lbs.).

NOTE: Using a flat-bladed tool, push bolt boot over shoulder of caliper bolt. Bolt boot must be securely in groove of pin bolt.

5. Brake hose bolt, if removed. Tighten bolt to 54 Nm (40 ft. lbs.).

NOTE: Replace copper gaskets.

6. Remove wheel nuts securing rotor to hub.
7. Tires and wheels.

NOTE: Align previous marks on wheel and hub.

8. Lower vehicle.
9. Fill master cylinder to proper level with clean brake fluid.
10. Bleed caliper. Service and Repair


11. Inspect hydraulic brake system for brake fluid leaks.