Removal & Installation
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.
Raise the vehicle and support safely.
Remove the appropriate tire and wheel assembly.
Remove the bolt attaching the brake hose to the caliper. Plug the brake hose to prevent brake fluid loss.
Remove the caliper support mounting bolts and lift the caliper/support assembly from the knuckle.
Position the caliper assembly onto the knuckle and install the bolts. Make sure the rotor fits between the brake pads. Torque the bolts to:
1996-01: 53-72 ft. lbs. (72-97 Nm).
2002-03: 124-137 ft. lbs. (169-186 Nm)
2004: 107-136 ft. lbs. (145-185 Nm)
2005: 136 ft. lbs. (185 Nm)
Using new copper washers, connect the brake hose to the caliper. Torque the brake hose attaching bolt to 12-14 ft. lbs. (17-20 Nm).
Bleed the brake system.
Apply the brake pedal and inspect the system. Ensure proper operation and no leakage.
Install tire and wheel assembly. Lower the vehicle and road-test.
Fig. Exploded view of the front brake components-2004 model shown