See Figures 1 through 10
- Disconnect the negative battery cable.
- Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
- Raise the vehicle and support safely.
- Remove the appropriate tire and wheel assembly. For rear disc brakes, loosen the parking brake cable adjustment from inside the vehicle.
If replacement or overhaul of the caliper is necessary, disconnect the brake hose from the caliper as follows:
- Hold the nut on the brake hose side and loosen the flared brake line nut.
- Remove the brake hose from the caliper.
- Remove the caliper guide and lock pins. Lift the caliper and slide the assembly toward the inside of the wheel well until it separates from the lock pin.
- If replacing the brake pads, suspend the caliper from the body with a suitable piece of wire. It is not necessary to disconnect the brake hose.
- Position the caliper on the caliper support. Install the guide pin and lock pin. On some vehicles, there are markings to distinguish the guide and locking pins. Identification marks may also appear on the bolt heads. They should be installed in their original locations.
For front disc brakes, tighten the caliper retainers as follows:
- For 1990-94 vehicles, tighten the guide and locking pins to 23 ft. lbs. (32 Nm) on vehicles built up to May, 1989, and on vehicles built during and after May, 1989, tighten caliper guide and locking pins to 58-72 ft. lbs. (80-100 Nm).
- On 1995-98 vehicles, tighten the guide and locking pins to 65 ft. lbs. (88 Nm).
- For rear disc brakes, tighten the caliper retainers to 36-43 ft. lbs. (50-60 Nm).
- Install the brake hose onto the caliper with new washers in place. If equipped with brake hose retainer bolt, tighten bolt to 25 ft. lbs. (35 Nm) torque. If no bolt is used, tighten the brake hose fitting to 9-12 ft. lbs. (13-17 Nm) for 1990-94 vehicles. For 1995-98 vehicles, tighten the brake hose fitting to 11 ft. lbs. (15 Nm).
Do not twist the brake hose during installation.
- Install the wheel and tire assembly. Carefully lower the vehicle and connect the negative battery cable.
- If the brake line was disconnected, properly bleed the brake system.
See Figures 11 through 18
Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.
- Remove the caliper from the vehicle and place on a clean workbench.
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.
The first method is as follows:
- Stuff a shop towel or a block of wood into the caliper to catch the piston.
- Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
- For the second method, you must rotate the piston to retract it from the caliper.
- If equipped, remove the anti-rattle clip.
- Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
- Remove the piston seals from the groove in the caliper bore.
- Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
- Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
- Use crocus cloth to polish out light corrosion from the piston and bore.
- Clean all parts with denatured alcohol and dry with compressed air.
- Lubricate and install the bleeder valve and cap.
- Install the new seals into the caliper bore grooves, making sure they are not twisted.
- Lubricate the piston bore.
- Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
- Use a suitable driving tool to seat the boots in the housing.
- Install the caliper in the vehicle.
- Install the wheel and tire assembly, then carefully lower the vehicle.
- Properly bleed the brake system.