Astro, Safari 1997-2005

Brake Caliper

Print

Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder reservoir.
  4.  
  5. Remove tire and wheel assembly.
  6.  
  7. Disconnect brake fluid line and plug it.
  8.  
  9. Remove bolts retaining the caliper to the rotor.
  10.  
  11. Remove caliper from the rotor.
  12.  
  13. Remove disc brake pads from the caliper.
  14.  
  15. Remove disc brake pad retaining clips from inside the caliper.
  16.  

To install:

  1. Clean and lubricate the sleeves and bushings with silicon grease.
  2.  
  3. Install sleeves and bushings.
  4.  
  5. Install pads in the caliper.
  6.  
  7. Install caliper in position over the rotor.
  8.  
  9. Install mounting bolts and tighten the bolts to 38 ft. lbs. (51 Nm) for single piston calipers; 85 ft. lbs. (115 Nm) for dual piston calipers.
  10.  
  11. Connect fluid lines to the caliper, if disconnected, and tighten to 33 ft. lbs. (45 Nm).
  12.  
  13. Install wheel and tire assembly.
  14.  
  15. Refill the master cylinder to the correct level. Bleed the brake system if the fluid lines were disconnected from the caliper.
  16.  

  1. Remove 2 / 3 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Raise and support the vehicle safely. Remove the tire and wheel assembly.
  4.  
  5. Disconnect and plug the caliper fluid line. Remove the bolts retaining the caliper to the rotor. Remove the caliper from the rotor.
  6.  
  7. Remove the disc brake pads from the caliper. Remove the disc brake pad retaining clips from inside the caliper.
  8.  

To install:

  1. Clean and lubricate the sleeves and bushings with silicon grease. Install the pads in the caliper.
  2.  
  3. Install the caliper in position over the rotor and install the mounting bolts. Tighten the mounting bolts to 38 ft. lbs. (51 Nm).
  4.  
  5. Connect the fluid lines to the caliper, if disconnected, and tighten to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the wheel and tire assembly.
  8.  
  9. Lower the vehicle and refill the master cylinder to the correct level. Bleed the brake system if the fluid lines were disconnected from the caliper.
  10.  

 
label.common.footer.alt.autozoneLogo