REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Drain 2 / 3 of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid.
- Raise the vehicle so that the wheel to be worked on is off the ground. Support the vehicle with jackstands.
- Remove the front wheels.
- Place a C-clamp on the caliper so that the solid end contacts the back of the caliper and the screw end contacts the metal part of the outboard brake pad.
- Tighten the clamp until the caliper moves far enough to force the piston to the bottom of the piston bore. This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.
- Remove the C-clamp.
Do not push down on the brake pedal or the piston and brake pads will return to their original positions up against the rotor.
- Remove both of the allen head mounting bolts and lift the caliper off the rotor.
If just the brake pads are being replaced, it is not necessary to remove the caliper assembly entirely from the vehicle. Do not remove the brake line. Rest the caliper on the front spring or other suitable support. Do not allow the brake hose to support the weight of the caliper.
- If the caliper is being removed in order to be rebuilt, then it is necessary to disconnect the brake fluid hose. Clean the brake fluid hose-to-caliper connection thoroughly. Remove the hose-to-caliper bolt. Cap or tape the open ends to keep dirt out. Discard the copper gaskets; get new ones!
- Install the caliper in the reverse order of removal. Torque the mounting bolts to 35 ft. lb.
If the brake fluid hose was disconnected, it will be necessary to bleed the hydraulic system.
See Figures 4 through 9
- Remove the caliper assembly and remove the brake pads. If the pads are to be reused, mark their location in the caliper.
- Clean the caliper exterior with clean brake fluid. Drain any residual fluid from the caliper and place it on a clean work surface.
Removal of the caliper piston requires the use of compressed air. Do not, under any circumstances, place your fingers in front of the piston in any attempt to catch or protect it when applying compressed air to remove the piston.
- Pad the interior of the caliper with clean cloths. Use several cloths and pad the interior well to avoid damaging the piston when it comes out of the bore.
- Insert an air nozzle into the inlet hole in the caliper and gently apply air pressure on the piston to push it out of the bore. Use only enough air pressure to ease the piston out of the bore.
- Pry the dust boot out of the bore with a screwdriver. Use caution during this operation to prevent scratching the bore. Discard the dust boot.
- Remove the piston seal from the piston bore and discard the seal. Use only nonscratching implements such as a pencil, wooden stick or a piece of plastic to remove the seal. Do not use a metal tool, as it could very easily scratch the bore.
- Remove the bleeder screw. Remove and discard the sleeves and rubber bushings from the