REMOVAL & INSTALLATION
Kelsey Hayes Caliper
- Loosen the lug nuts on the front wheels.
- Raise and support the vehicle.
- Remove the wheels.
- Take out the caliper guide pins.
- Remove the caliper by slowly sliding the caliper off the brake disc. Hang the caliper by a piece of stiff wire. Do not allow it to hang by the brake line.
- Remove the outboard brake pad from the adaptor.
- Remove the disc from the studs.
- Slide the inboard pad out of the adaptor.
- Place the new pads in the adaptor.
- Loosen the rear cap of the master cylinder reservoir and slowly push the caliper pistons back into the housing.
- Hold the outboard lining in position and carefully slide the caliper into position on the adaptor.
- Install the guide pins (lightly lubricated with silicone grease) and anti-rattle springs. The anti-rattle spring clips are installed with the closed loop toward the center of the car.
- Bleed the brakes.
- Install the wheels.
- Pump the pedal several times to remove clearance between pads and rotors.
- Raise and support the front end on jackstands.
- Remove the front wheels.
- Remove the caliper guide pin by unscrewing it until it is free from the threads, then pull it out of the caliper adapter.
- Using a small prybar, gently wedge the caliper away from the rotor, breaking the adhesive seals.
- Slowly slide the caliper away from the rotor and off the caliper adapter. Support the caliper securely by hanging it from the body with wire (this is necessary to keep its weight from damaging the brake hose).
- Slide the outboard pad off the caliper adapter. Then remove the disc by simply sliding it off the wheel studs.
- Remove the inboard pad by sliding it off the caliper adapter.
- If the caliper is to be removed, disconnect and cap the brake line. Then, remove it from the hanger and remove it.
- Lubricate both bushing channels with silicone grease.
- Remove the protective paper backing from the anti-squeal surfaces on both pads. Install the inboard pad on the adapter. Be careful to keep grease from the bushing channels from getting onto the pad as you do this.
- Install the rotor onto the wheel studs of the steering knuckle. Install the outboard pad in the caliper and carefully slide it into place over the rotor.
- If necessary, reconnect the brake line or remove the caliper from the hanger. Lower the caliper into position over the rotor and pads. Install the guide pin and tighten it to 35 ft. lbs. (47 Nm).
- Install the wheels and tighten the lugs to half the specified torque in a crisscross pattern. Then, tighten the lugs to full torque 95 ft. lbs. (129 Nm). If the brake line was disconnected, bleed the system thoroughly as described above. Pump the brake pedal several times to ensure that the brake pads seat against the rotor.
- Raise and safely support front the car.
- Remove the front wheels.
- Remove the hold-down spring from the caliper by pushing in at the middle of the spring and pushing it outwards.
- Loosen, but do not remove the caliper guide pins until the caliper is free from the mount. removal of the guide pins is necessary only if the bushings or sleeves require replacement.
- Lift the caliper out and away from the disc rotor. The inboard pad will remain in the caliper.
- Support the caliper so that the strain is on the hose. Remove the inboard pad from the caliper. Lift the outboard pad from the adapter.
- Push the piston back into the caliper bore. Install the inboard pad with the clamp locating it in the caliper piston.
- Install the outboard pad in the adapter. Position the caliper over the rotor and secure with guide pins. Carefully tighten the guide pins to 18-22 ft. lbs. (24-30 Nm). Install the hold-down spring. Mount the front wheels and lower the vehicle.
- Pump the brake pedal several times until a firm pedal is obtained. Check the master cylinder level and road test the vehicle.
Disc pads (lining and shoe assemblies) should be replaced in axle sets (both wheels) when the thickness of the shoe and lining is less than 5 / 16 in. (8mm).
Note that disc pads in floating caliper type brakes may wear at an angle, and measurement should be made at the narrow end of the taper. Tapered linings should be replaced if the taper exceeds 1 / 8 in. (3mm) from end-to-end (the difference between the thickest and thinnest points).
Always replace both sets on each wheel whenever one pad needs replacing.