Honda CRV/Odyssey 1995-2000 Repair Information

Brake Caliper

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REMOVAL & INSTALLATION



Do not allow the master cylinder reservoir to empty. An empty reservoir will allow air to enter the brake system and complete system bleeding will be required.


CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surface with compressed air! Avoid physical contact or inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Use a siphon or clean turkey baster to remove about half of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle, then remove the tire and wheel assembly.
  4.  
  5. Unfasten the caliper mounting bolts, then remove the caliper assembly from the rotor.
  6.  
  7. Remove the brake pads and shims.
  8.  
  9. If the caliper is to be completely removed from the vehicle for replacement or overhaul, remove the brake hose attaching bolt, then disconnect the brake hose from the caliper and plug the hose to prevent fluid contamination or loss.
  10.  
  11. Remove the caliper and mounting bracket from the vehicle. If the caliper is only removed for access to other components or for pad replacement, support the caliper using mechanic's wire so that there is no strain on the brake hose, and leave the brake hose attached.
  12.  
  13. Remove the caliper mounting bracket bolts and lift the caliper off the support bracket.
  14.  

See Figures 1 through 5

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Fig. Fig. 1: Use a wrench to loosen the caliper mounting bracket bolts



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Fig. Fig. 2: Once the bolts have been removed, lift the caliper mounting away from the brake rotor



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Fig. Fig. 3: Never let the caliper hang by the brake hose. Always suspend if with a piece of wire so there is no tension on the hose



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Fig. Fig. 4: Exploded view of the front brake caliper and related components- CRV model shown



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Fig. Fig. 5: Pull the rear brake caliper away from the mount-4-cylinder Odyssey models

To install:
  1. Completely retract the piston into the caliper using a large C-clamp or other suitable tool.
  2.  
  3. Clean and lubricate both steering knuckle abutments or support brackets with a coating of multi-purpose grease.
  4.  
  5. Position the caliper and brake pad assembly over the brake rotor. Be sure to properly install the caliper assembly into the abutments of the steering knuckle or support bracket. Be sure the caliper guide pin bolts, rubber bushings and sleeves are clear of the steering knuckle bosses.
  6.  
  7. Fill the master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system as outlined in this section.
  8.  
  9. Install the wheel and tire assembly.
  10.  
  11. Carefully lower the vehicle, then tighten the lug nuts to the proper specifications.
  12.  
  13. Depress the brake pedal using short 2 inch (50 mm) strokes, in repetitions of 3-4 times until the brake linings are seated and to restore pressure in the system.
  14.  


CAUTION
Do not move the vehicle until a firm pedal is obtained.

  1. Road test the vehicle and check for proper brake operation.
  2.  

OVERHAUL



Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  

See Figures 6, 7 and 8

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Fig. Fig. 6: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Fig. 7: Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. Fig. 8: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  

See Figures 9 and 10

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Fig. Fig. 9: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 10: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  

See Figure 11

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Fig. Fig. 11: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To install:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  

See Figure 12

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Fig. Fig. 12: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  

See Figure 13

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Fig. Fig. 13: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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