REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Raise and safely support the vehicle. Remove the front wheel(s).
- If equipped with a hollow brake hose retaining bolt, remove the bolt and plug the brake hose.
- If the brake line screws into the caliper, loosen the brake line fitting that connects the brake hose to the brake line at the frame bracket. Remove the retaining clip from the hose and bracket and disengage the hose from the bracket. Unscrew the hose from the caliper.
- 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 shoe against the rotor's braking surface.
- Lubricate the inside of the locating pin with silicone dielectric grease. Install the caliper locating pins and tighten to 45-65 ft. lbs. (61-88 Nm).
- If equipped with a hollow brake hose retaining bolt, install new copper washers on each side of the brake hose fitting outlet and install the bolt through the hose fitting and into the caliper. Tighten the bolt to 25 ft. lbs. (34 Nm).
- If the brake hose screws into the caliper, carefully start the threads and tighten to 20-30 ft. lbs. (28-41 Nm).
This is a special, self-sealing fitting that does not require a gasket. When the hose is correctly tightened, 1 or 2 threads will still show at the caliper. It is not necessary for the hose fitting to be flush with the caliper for a good seal; do not overtighten.
- Bleed the brake system, install the wheel and lower the vehicle.
- To position the brake pads, apply the brake pedal several times before moving the vehicle.
See Figures 4, 5, 6 and 7
- Clean the outside of the caliper in alcohol after removing it from the vehicle and removing the brake pads.
- Drain the caliper through the inlet port.
- Roll some thick shop cloths or rags and place them between the piston and the outer legs of the caliper.
- Apply compressed air to the caliper inlet port until the piston comes out of the bore. Use low air pressure to avoid having the piston pop out too rapidly and possibly causing injury
- If the piston becomes cocked in the bore and will not come out, use a soft mallet to tap it straight. Do not use a sharp tool or attempt to pry the piston out. Once straightened, reapply the compressed air.
- Remove the boot from the piston and remove the seal from the caliper bore.
- Clean the piston and caliper in alcohol.
- Lubricate the piston seal with clean brake fluid, and position the seal in the groove in the cylinder bore.
- Coat the outside of the piston and both of the beads of the dust boot with clean brake fluid. Insert the piston through the dust boot until the boot is around the bottom (closed end) of the piston.
- Hold the piston and dust boot directly above the caliper bore and use your fingers to work the bead of the dust boot into the groove near the top of the cylinder bore.
- After the bead is seated in the groove, press straight down on the piston until it bottoms in the bore. Be careful not to cock the piston. If necessary, use a C-clamp with a block of wood inserted between the clamp and the piston to bottom the piston.
- Install the brake pads and the caliper. Bleed the hydraulic system and re-center the pressure differential valve. Do not drive the vehicle until a firm brake pedal is achieved.