REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 6
- Remove the master cylinder cap and check the fluid level in the reservoir. Remove the brake fluid until the reservoir is half full. Discard the removed fluid.
- Raise and safely support the vehicle. Remove the wheel and tire assembly from the rotor mounting face, being careful not to damage or interfere with the caliper, rotor shield or the steering knuckle.
- For vehicles through 1993, remove the caliper locating pins using Torx® Drive Bit D79P-2100-T40, or equivalent. For 1994-95 vehicles, remove the rear brake pin retainers.
It is not necessary to disconnect the brake lines.
- Lift the caliper assembly from the integral knuckle, anchor plate and 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.
Do not pry directly against the caliper piston or damage will result.
- Remove the inner and outer 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.
- Use a 4 in. (10cm) C-clamp and a wood block about 2 3 / 4 in. x 1 in. (7cm x 2.5cm) and about 3 / 4 in. (19mm) thick to seat the caliper piston in its bore. This must be done to provide clearance for the caliper assembly with the new brake pads to fit over the rotor during installation. Care must be taken during this procedure to prevent damage to the caliper piston. Do not allow metal or sharp objects to come into direct contact with the piston surface or damage will result.
- Remove all rust buildup from the inside caliper legs (brake shoe contact area). Install the inner pad in the caliper piston. Do not bend the pad clips during installation in the piston or distortion and rattles can occur. Install the outer pad. Make sure the clips are properly seated.
- Install the caliper over the rotor as outlined later in this section. Install the caliper locating pins or rear brake pin retainer, as applicable. Tighten the rear brake pin retainer to 25 ft. lbs. (34 Nm).
- Install the wheel and tire assembly. Lower the vehicle, then, using a torque wrench, tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm).
- Pump the brake pedal prior to moving the vehicle to position the brake linings. Refill the master cylinder.
- Remove the pads from the caliper.
- Check both the inner and outer pads for excessive wear. Please refer to the specification chart in this section.
- If only one pad is found to be defective, replace both of them on each side (complete axle set), not just the defective one.