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 anchor bracket mounting bolts, per caliper. Once removed, these parts lose 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:
of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid.
Front wheel and tire assembly
2 disc brake caliper anchor bracket mounting bolts and discard. Lift the caliper assembly from the disc brake rotor using a rotating motion. Suspend the caliper inside the fender housing with wire. Do not allow the caliper to hang from the brake hose.
Inner and outer disc brake pads. Inspect the rotor braking surfaces for scoring and machine as necessary. Refer to the minimum rotor thickness specification when machining. If machining is not necessary, hand-sand the glaze from the braking surfaces with medium grit sandpaper. Make sure to wear an approved respirator.
Fig. Removal of rear disc brake pads from caliper
If installing new brake pads, use a C-clamp, and an old brake pad or a wood block to seat the caliper piston in its bore. Do not allow metal or sharp objects to come into direct contact with the plastic caliper piston surface or damage will result.
Fig. Compress brake caliper piston as shown
Remove all rust buildup from the inside of the caliper legs.
Make sure the anti-rattle spring is seated in the caliper lining inspection opening and that it is installed from the lining side.
Install or connect the following:
Inner disc brake pad to the caliper piston. Do not bend the pad clips during installation in the piston or distortion and rattles can occur. Install the outer disc brake pad. Make sure the clips are properly seated.
Caliper over the rotor and install 2 new anchor bracket mounting bolts. Torque the bolts to 118 ft. lbs. (160 Nm).
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 prior to moving the vehicle to seat the brake pads.
Fill the master cylinder reservoir with clean DOT 3 brake fluid from a closed container.
If the disc brake calipers were replaced or repaired be sure to bleed the system.
Road test the vehicle and check for proper brake system operation.