Montana, Silhouette, Venture 2000-2005

Brake Caliper

Print

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. Inspect the fluid level in the brake master cylinder reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the tire and wheel.
  8.  
  9. Install two nuts to retain the rotor to the hub.
  10.  
  11. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
  12.  
  13. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
  14.  
  15. Remove the brake hose bolt.
  16.  
  17. Remove the brake hose from the brake caliper.
  18.  
  19. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  20.  
  21. Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and contamination.
  22.  
  23. Clean off any dirt or corrosion on the brake caliper near the brake hose fitting.
  24.  
  25. Remove the brake caliper bolts.
  26.  
  27. Remove the brake caliper from the brake caliper bracket.
  28.  
  29. Inspect the brake caliper piston boot.
  30.  
  31. Inspect the brake caliper bolt boots.
  32.  
  33. Inspect the caliper bolts for corrosion or damage.
    NOTE
    Do not attempt to polish away the corrosion.

  34.  

To install:

  1. Ensure that the caliper bolt bushings and the caliper bolt boots are properly installed.
  2.  
  3. Install the brake caliper to the brake caliper bracket.
  4.  
  5. Lubricate the brake caliper bolt shaft. Do not lubricate the threads.
  6.  
  7. Lubricate the brake caliper bolt boots in the brake caliper bracket.
  8.  
  9. Install the brake caliper bolts. Tighten the bolts to 44 Nm (32 ft. lbs).
  10.  
  11. Use a flat-bladed tool in order to install the brake caliper bracket boot over the shoulder of the brake caliper bolt.
  12.  
  13. Remove the plugs in the brake hose end.
    NOTE
    Install NEW copper brake hose gaskets.

  14.  
  15. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
  16.  
  17. Install the brake hose bolt to the brake caliper.
  18.  
  19. Remove the nuts securing the rotor to the hub.
  20.  
  21. Install the tire and wheel.
  22.  
  23. Lower the vehicle.
  24.  
  25. Fill the master cylinder to the proper level with clean brake fluid.
  26.  
  27. Bleed the brake system.
  28.  
  29. Pump the brake pedal ( 3 / 4 of a full stroke) as many times as necessary to obtain a firm brake pedal.
  30.  
  31. Apply approximately 778 Nm (175 ft. lbs.) of force to the brake pedal for ten seconds.
  32.  
  33. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.
  34.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.

  2.  
  3. Remove the tire and wheel assembly

    Click image to see an enlarged view

    Fig. Showing the park brake system equalizer

  4.  
  5. Release tension from the park brake system at the equalizer
  6.  
  7. Remove or disconnect the following:

    Front and rear cables from one another at the connector clip
     
    Park brake cable from the park brake lever on the brake caliper
     
    Park brake cable from the caliper bracket
     
    Brake hose to caliper bolt
     
    Brake hose from the brake caliper
     
    Discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end
     
    Plug the opening in the brake caliper and brake hose to prevent fluid loss and/or contamination
     
    Brake caliper bolts
     
    Brake caliper
     

  8.  

To install:

  1. Align the indents on the piston face to match the pin on the brake pad.

    Click image to see an enlarged view

    Fig. Aligning indents on piston face during caliper installation

  2.  
  3. Inspect the bracket bolt guide assembly.
  4.  
  5. Inspect the brake pad hardware and replace, if necessary.
  6.  
  7. Install or connect the following:
    NOTE
    Install NEW copper brake hose gaskets.



    Brake caliper onto the caliper bracket ensuring that the guide boots are not damaged
     
    Brake caliper bolts and tighten the brake caliper bolts to 25 ft. lbs. (34 Nm)
     



    Brake hose bolt and the NEW copper brake hose gaskets to the brake hose
     
    Brake hose to caliper bolt to the brake caliper. When installing the rear brake hose to caliper, hold the hose up while tightening. Tighten the brake hose to caliper bolt to 30 ft. lbs. (40 Nm)
     
    Park brake cable into the park brake bracket on the caliper
     
    Park brake cable to the park brake lever on the brake caliper
     

  8.  
  9. Bleed the brake system.
  10.  
  11. With the engine OFF, gradually apply the brake pedal to approximately  2 / 3 of its travel distance. Slowly release the brake pedal.
  12.  
  13. Wait 15 seconds, then repeat steps until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  14.  
  15. Adjust the park brake system.
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Lower the vehicle.
  20.  

 
label.common.footer.alt.autozoneLogo