Continental 2000-2002

Brake Caliper

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Removal & Installation




CAUTION
The air suspension switch, located in the left side of the luggage compartment, must be turned OFF before raising the vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs that may result in shifting of the vehicle during service.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove brake fluid from the brake master cylinder reservoir until the reservoir is 1 / 2 full.
  4.  
  5. Turn the air suspension switch, located in the left side of the luggage compartment, to the OFF position.
  6.  
  7. Remove the wheel and tire assembly.
  8.  
  9. Mark the disc brake caliper to ensure that it is reinstalled in the correct location.
  10.  
  11. Remove the hollow bolt connecting the brake hose to the disc brake caliper and plug the brake hose. Discard the 2 copper sealing washers.
  12.  
  13. Remove the caliper locating pins and lift the caliper off the rotor using a rotating motion.

    Click image to see an enlarged view

    Fig. Front disc brake caliper, pads and related components

  14.  

To install:

  1. Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp.
    NOTE
    Make sure the clip-on insulators are attached to the brake pads.

  2.  
  3. Install the disc brake pads to the caliper. Make sure the brake pad insulators are correctly attached to the brake pad plate.
  4.  
  5. Position the disc brake caliper and pad assembly above the rotor and install it with a rotating motion. Make sure the inner and outer pads are properly positioned and the outer anti-rattle spring is properly positioned.
  6.  
  7. Lubricate the locating pins and the inside of the insulators with silicone grease. Torque the locating pins to 25 ft. lbs. (34 Nm).
  8.  
  9. Remove the plug and install the brake hose to the disc brake caliper. Use 2 new copper washers and torque the hollow bolt to 30-40 ft. lbs. (41-54 Nm).
  10.  
  11. Bleed the brake system, filling the master cylinder as required.
  12.  
  13. Install the wheel and tire assembly; torque the nuts to 85-104 ft. lbs. (115-142 Nm).
  14.  
  15. Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
  16.  
  17. Turn the air suspension service switch to the ON position.
  18.  
  19. Road test the vehicle and check for proper brake system operation.
  20.  

  1. Raise and safely support the vehicle. Remove the front wheel and tire assembly.
  2.  
  3. Loosen the brake line fitting that connects the brake hose to the brake line at the frame bracket. Plug the brake line. Remove the retaining clip from the hose and bracket and disengage the hose from the bracket.
  4.  
  5. Remove the hollow bolt attaching the brake hose to the caliper and remove the brake hose. Discard the sealing washers.
  6.  
  7. Remove the caliper locating pins and remove the caliper. If removing both calipers, mark the right and left sides so they may be reinstalled correctly.
  8.  

To install:

  1. Install the caliper over the rotor with the outer brake pad against the rotor's braking surface. This prevents pinching the piston boot between the inner brake pad and the piston.
  2.  
  3. Lubricate the locating pins and the inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins and thread them into the spindle/anchor plate assembly by hand.
  4.  
  5. Tighten the caliper locating pins to 45-65 ft. lbs. (61-88 Nm).
  6.  
  7. Install new sealing washers on each side of the brake hose fitting outlet and install the hollow bolt, through the hose fitting and into the caliper. Tighten the bolt to 30 ft. lbs. (41 Nm).
  8.  
  9. Position the other end of the brake hose in the bracket and install the retaining clip. Make sure the hose is not twisted.
  10.  
  11. Remove the plug from the brake line, connect the brake line to the brake hose and tighten the fitting nut to 10-18 ft. lbs. (13-24 Nm).
  12.  
  13. Bleed the brake system, install the wheel and tire assembly and lower the vehicle.
  14.  
  15. Apply the brake pedal several times before moving the vehicle, to position the brake pads.
  16.  
  17. Road test the vehicle.
  18.  



Click image to see an enlarged view

Fig. Front disc brake caliper assembly

 
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