Removal & Installation
If the vehicle is equipped with air suspension, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury.
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.
Before continuing with this procedure, make sure to have available, 2 new disc brake caliper guide pin bolts and 2 banjo bolt sealing washers, per caliper. Once removed, these parts loose their torque holding ability or retention capability and must not be reused.
If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the
position before raising the vehicle.
Remove or disconnect the following:
Front wheel and tire assembly
Banjo bolt securing the brake hose from the disc brake caliper. Plug the brake hose. Discard the sealing washers.
2 disc brake caliper guide pin bolts and discard. If removing both calipers, mark the right and left sides so they may be reinstalled correctly.
Disc brake caliper off of the anchor plate
Fig. Front brake caliper assembly
Front brake caliper components:
Brake caliper flow bolt
Copper washers (2 required)
Brake caliper bolts (2 required)
Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp.
Install or connect the following:
Disc brake pads to the caliper. Make sure that the brake pad insulators are correctly attached to the brake pad plate.
Disc brake caliper onto the anchor plate. Make sure the inner and outer pads are properly positioned and the anti-rattle spring is properly positioned. The caliper bleed screw should be positioned on top of the caliper when assembled on the vehicle.
2 new caliper guide pin bolts and torque to 27 ft. lbs. (36 Nm)
Brake hose, after unplugging it, to the disc brake caliper using 2 new copper sealing washers on the banjo bolt. Torque the bolt to 35 ft. lbs. (48 Nm).
Bleed the brake system, filling the master cylinder as required. Only use clean DOT 3 brake fluid from a sealed container.
Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 100 ft. lbs. (136 Nm).
If equipped with air suspension, turn the air suspension switch to the
Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
Road test the vehicle and check for proper brake system operation.