ION, L-Series, S-Series 1999-2005

Brake Caliper

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Remove the rear wheel and tire assembly.
  2.  
  3. Disconnect the brake hose from the caliper and discard the 2 copper washers.
  4.  
  5. Plug the openings to prevent system contamination or excessive fluid loss.
  6.  
  7. Slip the end of the parking cable off the parking brake lever.
  8.  
  9. Remove the cable outer housing from the cable bracket with SA9151BR cable release tool.
  10.  
  11. Remove the lock pin and guide pin.
  12.  
  13. Remove the caliper from the support, being careful not to damage the pin boots.
  14.  
  15. Remove the pin boots from the caliper support for inspection and lubrication.
  16.  

To install:

  1. Make sure the piston is bottomed in the bore. Do not compress the piston using a C-clamp; instead the piston must be rotated into the caliper on its threads using a piston driver tool.
  2.  
  3. If removed, install the brake pads and clips to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease.
  6.  
  7. Install the pin boots into the caliper support, using the pin to assure that the boot passes all the way through the support.
  8.  
  9. Position the caliper onto the caliper support.
  10.  
  11. Lubricate the non-threaded portion of the guide and lock pins. Install the pins and torque to 27 ft. lbs. (36 Nm).
  12.  
  13. Install the brake hose using new copper washers and torque the fitting bolt to 36 ft. lbs. (49 Nm).
  14.  
  15. Connect the parking brake cable.
  16.  
  17. Properly bleed the hydraulic brake system.
  18.  
  19. Install the wheel and tire assembly.
  20.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back.
  8.  
  9. Release the tension from the park brake cables. With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod.
  10.  
  11. Raise and support the vehicle.
  12.  
  13. Remove the tire and wheel assembly.
  14.  
  15. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  16.  
  17. Release the park brake cable end from the lever on the caliper.

    Click image to see an enlarged view

    Fig. Release the retaining tabs securing the park brake cable to the bracket on the caliper.

  18.  
  19. Release the retaining tabs securing the park brake cable to the bracket on the caliper.
  20.  
  21. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  22.  
  23. Tighten the C-clamp just enough to compress the caliper piston 0.039 in (1 mm) of travel only.
  24.  
  25. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake hose-to-caliper bolt (1) from the brake caliper, the brake hose (2) from the brake caliper, and the two copper brake hose gaskets (3)

  26.  
  27. Remove the brake hose-to-caliper bolt from the brake caliper.
  28.  
  29. Remove the brake hose from the brake caliper.
  30.  
  31. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  32.  
  33. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
  34.  
  35. While using a wrench on the flats of the caliper guide pins, remove the brake caliper guide pin bolts.
  36.  
  37. Remove the brake caliper from the caliper bracket.
  38.  
  39. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  40.  
  41. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  42.  

To install:

  1. Install the brake caliper to the caliper bracket.
  2.  
  3. While using a wrench on the flats of the caliper guide pins, install the brake caliper guide pin bolts and tighten the bolts to 25 ft. lbs. (34 Nm).
  4.  
  5. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs.
  6.  
  7. Secure the park brake cable end to the lever on the caliper.
  8.  
  9. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    Do not reuse the copper brake hose gaskets.

  10.  
  11. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  12.  
  13. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper, and tighten the bolt to 35 ft. lbs. (48 Nm).
  14.  
  15. Bleed the hydraulic brake system.
  16.  
  17. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Lower the vehicle.
  22.  
  23. With the engine OFF , gradually apply the brake pedal to approximately two-thirds of its travel distance.
  24.  
  25. Slowly release the brake pedal.
  26.  
  27. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  28.  
  29. Adjust the park brake cable tension.
  30.  
  31. Position the park brake lever boot to the floor console and press the boot retainer into place to secure
  32.  

  1. Remove the rear wheel and tire assembly.
  2.  
  3. Disconnect the brake hose from the caliper and discard the 2 copper washers.
  4.  
  5. Plug the openings to prevent system contamination or excessive fluid loss.
  6.  
  7. Slip the end of the parking cable off the parking brake lever.
  8.  
  9. Remove the cable outer housing from the cable bracket with SA9151BR cable release tool.
  10.  
  11. Remove the lock pin and guide pin.
  12.  
  13. Remove the caliper from the support, being careful not to damage the pin boots.
  14.  
  15. Remove the pin boots from the caliper support for inspection and lubrication.
  16.  

To install:

  1. Make sure the piston is bottomed in the bore. Do not compress the piston using a C-clamp; instead the piston must be rotated into the caliper on its threads using a piston driver tool.
  2.  
  3. If removed, install the brake pads and clips to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease.
  6.  
  7. Install the pin boots into the caliper support, using the pin to assure that the boot passes all the way through the support.
  8.  
  9. Position the caliper onto the caliper support.
  10.  
  11. Lubricate the non-threaded portion of the guide and lock pins. Install the pins and torque to 27 ft. lbs. (36 Nm).
  12.  
  13. Install the brake hose using new copper washers and torque the fitting bolt to 36 ft. lbs. (49 Nm).
  14.  
  15. Connect the parking brake cable.
  16.  
  17. Properly bleed the hydraulic brake system.
  18.  
  19. Install the wheel and tire assembly.
  20.  

  1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back.
  8.  
  9. Release the tension from the park brake cables. With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod.
  10.  
  11. Raise and support the vehicle.
  12.  
  13. Remove the tire and wheel assembly.
  14.  
  15. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  16.  
  17. Release the park brake cable end from the lever on the caliper.

    Click image to see an enlarged view

    Fig. Release the retaining tabs securing the park brake cable to the bracket on the caliper.

  18.  
  19. Release the retaining tabs securing the park brake cable to the bracket on the caliper.
  20.  
  21. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  22.  
  23. Tighten the C-clamp just enough to compress the caliper piston 0.039 in (1 mm) of travel only.
  24.  
  25. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake hose-to-caliper bolt (1) from the brake caliper, the brake hose (2) from the brake caliper, and the two copper brake hose gaskets (3)

  26.  
  27. Remove the brake hose-to-caliper bolt from the brake caliper.
  28.  
  29. Remove the brake hose from the brake caliper.
  30.  
  31. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  32.  
  33. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
  34.  
  35. While using a wrench on the flats of the caliper guide pins, remove the brake caliper guide pin bolts.
  36.  
  37. Remove the brake caliper from the caliper bracket.
  38.  
  39. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  40.  
  41. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  42.  

To install:

  1. Install the brake caliper to the caliper bracket.
  2.  
  3. While using a wrench on the flats of the caliper guide pins, install the brake caliper guide pin bolts and tighten the bolts to 25 ft. lbs. (34 Nm).
  4.  
  5. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs.
  6.  
  7. Secure the park brake cable end to the lever on the caliper.
  8.  
  9. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    Do not reuse the copper brake hose gaskets.

  10.  
  11. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  12.  
  13. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper, and tighten the bolt to 35 ft. lbs. (48 Nm).
  14.  
  15. Bleed the hydraulic brake system.
  16.  
  17. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Lower the vehicle.
  22.  
  23. With the engine OFF , gradually apply the brake pedal to approximately two-thirds of its travel distance.
  24.  
  25. Slowly release the brake pedal.
  26.  
  27. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  28.  
  29. Adjust the park brake cable tension.
  30.  
  31. Position the park brake lever boot to the floor console and press the boot retainer into place to secure
  32.  

 
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