Aurora 2001-2003

Brake Caliper

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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. Siphon 2 / 3 of the brake fluid out of the master cylinder reservoir.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Install 2 wheel nuts loosely to secure the rotor when the caliper is removed.
  6.  
  7. Remove the bolts securing the brake hose to the caliper and disconnect the brake hose from the caliper.
  8.  
  9. Plug the hose to prevent excessive fluid loss and possible fluid contamination.
  10.  
  11. Compress the piston into the caliper bore to provide clearance for removal.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the caliper from the anchor bracket.
  16.  
  17. If the caliper is being replaced remove the brake pads from the caliper or anchor bracket.
  18.  

To install:

Click image to see an enlarged view

Fig. Front caliper and brake pad components



Click image to see an enlarged view

Fig. Compressing the front caliper piston



Click image to see an enlarged view

Fig. Caliper mounting bolt and sleeve lubrication points

  1. Seat the caliper piston fully in its bore.
  2.  
  3. Install the brake pads in the caliper or anchor bracket.
  4.  
  5. Install the caliper on the anchor bracket and install the mounting bolts.
  6.  
  7. Torque the caliper mounting bolts to 63 ft. lbs. (85 Nm).
  8.  
  9. Reconnect the brake hose to the caliper using new washers. Torque the fitting bolt to 33 ft. lbs. (45 Nm).
  10.  
  11. Remove the 2 lug nuts securing the brake rotor.
  12.  
  13. Install the wheel and tire assembly and torque the wheel nuts to 100 ft. lbs. (140 Nm).
  14.  
  15. Refill the master cylinder with fluid and bleed the brake system.
  16.  
  17. Pump the brake pedal several times to seat the brake pads against the rotor. Verify no hydraulic leaks and a good firm brake pedal.
  18.  

  1. Siphon 2 / 3 of the brake fluid out of the master cylinder reservoir.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Install 2 wheel nuts loosely to secure the rotor when the caliper is removed.
  6.  
  7. Remove the bolts securing the brake hose to the caliper and disconnect the brake hose from the caliper.
  8.  
  9. Plug the hose to prevent excessive fluid loss and possible fluid contamination.
  10.  
  11. Compress the piston into the caliper bore to provide clearance for removal.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the caliper from the anchor bracket.
  16.  
  17. If the caliper is being replaced remove the brake pads from the caliper or anchor bracket.
  18.  

To install:

Click image to see an enlarged view

Fig. Front caliper and brake pad components-Riviera, Aurora



Click image to see an enlarged view

Fig. Compressing the front caliper piston-Riviera, Aurora



Click image to see an enlarged view

Fig. Caliper mounting bolt and sleeve lubrication points-Riviera, Aurora

  1. Seat the caliper piston fully in its bore.
  2.  
  3. Install the brake pads in the caliper or anchor bracket.
  4.  
  5. Install the caliper on the anchor bracket and install the mounting bolts.
  6.  
  7. Torque the caliper mounting bolts to 38 ft. lbs. (51 Nm). Torque the mounting bolts to 63 ft. lbs. (85 Nm).
  8.  
  9. Reconnect the brake hose to the caliper using new washers. Torque the fitting bolt to 33 ft. lbs. (45 Nm).
  10.  
  11. Remove the 2 lug nuts securing the brake rotor.
  12.  
  13. Install the wheel and tire assembly and torque the wheel nuts to 100 ft. lbs. (140 Nm).
  14.  
  15. Refill the master cylinder with fluid and bleed the brake system.
  16.  
  17. Pump the brake pedal several times to seat the brake pads against the rotor. Verify no hydraulic leaks and a good firm brake pedal.
  18.  

 
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