See Figure 1
REMOVAL & INSTALLATION
- Raise and support the front end on jackstands.
- Remove the wheels.
- Disconnect the rubber brake hose from the tubing at the frame mount. If the pistons are to be removed from the caliper, leave the brake hose connected to the caliper. Check the rubber hose for cracks or chafed spots.
- Plug the brake line to prevent loss of fluid.
- Remove the retaining screw, clip and antirattle spring that attach the caliper to the adaptor.
- Carefully slide the caliper out and away from the disc. Check the pads to be sure that they are reinstalled in the same position.
- Position the outboard shoe in the caliper. The shoe should not rattle in the caliper. If it does, or if any movement is obvious, bend the shoe tabs over the caliper to tighten the fit.
- Install the inboard shoe.
- Slide the caliper into position on the adaptor and over the rotor.
- Install the anti-rattle springs and retaining clips and torque the retaining screws to 16 ft. lbs.
The inboard shoe must always be installed on top of the retainer spring plate.
- Fill the system with fresh fluid and bleed the brakes.
- Remove the caliper from the rotor.
- If the pistons are to be removed, support the caliper on the upper control arm and surround it with towels to absorb the hydraulic fluid that will be lost.
- Carefully depress the brake pedal to hydraulically push the piston from its bore. Prop the pedal at any position below the first inch of travel to prevent further loss of fluid.
- Disconnect the plug and brake line after the first piston is removed.
- Mount the caliper in a vise equipped with soft jaws.
- Remove the dust boot.
- Using a small wooden of plastic pointed tool, work the piston seal out of its groove in the piston bore.
- Clean all parts in alcohol and allow to air dry.
- Dip a new piston seal in the lubricant supplied with the factory rebuilding kit or in clean brake fluid. Install the seal in the groove in the bore.
- Coat a new piston boot with lubricant and leave a generous amount inside the boot.
- Install the piston seal into the caliper by working it into the groove with your fingers only. At first sight, the seal will appear larger than the bore, but will snap into place when properly seated.
- Plug the high pressure inlet to the caliper and the bleeder screw hole and coat the piston with lubricant. Spread the boot with your fingers and work the piston into the boot, pressing down evenly.
- Remove the plug and carefully push the piston down until it hits bottom.
- Install the caliper on the vehicle, using the reverse order of removal.
- Be sure to install the inboard pad anti-rattle spring on top of the retainer spring plate. Bleed the brakes. Road test the van making several stops to wear any foreign material off of the pads.