- Raise the vehicle until the wheel and tire clear the floor. Place safety stands under the vehicle.
- Remove the wheel cover.
- Remove the wheel and tire from the hub and disc.
Brake shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
- Visually check the caliper for signs of leakage. If leakage is evident, the caliper should be overhauled or replaced.
- Install the wheel and tire assembly and tighten the wheel lug nuts. Install the wheel cover.
- Remove the safety stands and lower the vehicle.
REMOVAL & INSTALLATION
See Figure 1
- Raise and safely support the vehicle. Remove the front wheel and tire assembly.
- Loosen the brake line fitting that connects the brake hose to the brake line at the frame bracket. Plug the brake line. Remove the retaining clip from the hose and bracket and disengage the hose from the bracket.
- Remove the hollow bolt attaching the brake hose to the caliper and remove the brake hose. Discard the sealing washers.
- Remove the caliper locating pins and remove the caliper. If removing both calipers, mark the right and left sides so they may be reinstalled correctly.
- Install the caliper over the rotor with the outer brake pad against the rotor's braking surface. This prevents pinching the piston boot between the inner brake pad and the piston.
- Lubricate the locating pins and the inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins and thread them into the spindle/anchor plate assembly by hand.
- Tighten the caliper locating pins to 45-65 ft. lbs. (61-88 Nm).
- Install new sealing washers on each side of the brake hose fitting outlet and install the hollow bolt, through the hose fitting and into the caliper. Tighten the bolt to 30 ft. lbs. (41 Nm).
- Position the other end of the brake hose in the bracket and install the retaining clip. Make sure the hose is not twisted.
- Remove the plug from the brake line, connect the brake line to the brake hose and tighten the fitting nut to 10-18 ft. lbs. (13-24 Nm).
- Bleed the brake system, install the wheel and tire assembly and lower the vehicle.
- Apply the brake pedal several times before moving the vehicle, to position the brake pads.
- Road test the vehicle.
See Figures 2 through 10Disassembly
- Remove the front disc brake caliper from the vehicle and place it on a bench.
- Remove the brake pads from the caliper.
- Place a piece of wood between the caliper piston and the caliper bridge to cushion the piston's impact. Using an air nozzle, apply air pressure to the caliper fluid port to blow the piston out of its bore. If the piston is seized and cannot be forced from the caliper, tap lightly around the piston while applying air pressure.
Apply only enough air pressure to ease the piston out of the caliper. Excessive pressure can force the piston out of the caliper bore with enough force to cause personal injury. Never attempt to catch the piston by hand as it comes out of the bore.
Do not use a screwdriver or prybar to pry the piston out of the bore; damage to the piston may result.
- Remove the dust boot from the caliper.
- Remove and discard the rubber piston seal from the caliper bore.
- Clean all metal parts with isopropyl alcohol, then clean out and dry the grooves and passageways with compressed air. Make sure the caliper bore and component parts are thoroughly clean.
- Check the caliper bore and piston for damage or excessive wear. Replace the piston if it is pitted or scored, or on Police vehicles if the chrome plating is worn off. The piston should also be replaced if it does not meet the requirements.
- Apply a film of clean brake fluid to a new caliper piston seal and install it in the caliper bore. Make sure the seal is firmly seated in the groove and not twisted.
- Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore.
- Coat the piston with brake fluid. Using a C-clamp and a wood block, install the piston into the caliper bore. Make sure the piston is not cocked. Spread the dust boot over the piston as it is installed.
Never apply the C-clamp directly to the caliper piston; damage to the piston may result.
- Seat the dust boot in the piston groove. Make sure the dust boot is tight in the boot groove on the piston.
- Install the disc brake pads and install the caliper on the vehicle.