REMOVAL & INSTALLATION
1996-98 Sidekick, Tracker and X-90 models equipped with the Anti-Lock Brake System (ABS) require a scan tool to properly bleed the brake system. If you are servicing such a vehicle, please refer to the applicable ABS section located at the end of this section BEFORE you perform any brake procedures.
- Loosen all of the front wheel lug nuts 1 / 2 turn.
- Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
- Remove the front wheels.
- Clean the brake caliper with commercially available brake cleaning spray.
- Disconnect and plug the flexible brake line.
- Remove the caliper mounting bolts (guide pins), then remove the caliper from the brake pad mounting bracket.
- Install the caliper over the brake pads and mounting bracket.
- Install and tighten the mounting bolts (guide pins) to 19-21 ft. lbs. (25-30 Nm) for Samurai, Sidekick, Tracker and X-90 models, or the bottom bolt to 37 ft. lbs. (50 Nm) and the top bolt to 42 ft. lbs. (58 Nm) for Sidekick Sport models.
- Connect the hydraulic brake line, using two new washers, to the caliper. Tighten the flexible hose union bolt to 177-221 inch lbs. (20-25 Nm).
- Install the front wheels.
- Lower the vehicle, then fully tighten the front wheel lug nuts.
- Fill the brake reservoir and bleed the hydraulic brake system.
See Figures 5 through 12
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.