REMOVAL & INSTALLATION
Do not allow the master cylinder reservoir to empty. An empty reservoir will allow air to enter the brake system and complete system bleeding will be required.
- Use a siphon or clean turkey baster to remove about half of the brake fluid from the master cylinder.
- Raise and safely support the vehicle, then remove the tire and wheel assembly.
- Unfasten the caliper mounting bolts, then remove the caliper assembly from the rotor.
- Remove the brake pads and shims.
- If the caliper is to be completely removed from the vehicle for replacement or overhaul, remove the brake hose attaching bolt, then disconnect the brake hose from the caliper and plug the hose to prevent fluid contamination or loss.
- Remove the caliper and mounting bracket from the vehicle. If the caliper is only removed for access to other components or for pad replacement, support the caliper using mechanic's wire so that there is no strain on the brake hose, and leave the brake hose attached.
- Remove the caliper mounting bracket bolts and lift the caliper off the support bracket.
- Completely retract the piston into the caliper using a large C-clamp or other suitable tool.
- Clean and lubricate both steering knuckle abutments or support brackets with a coating of multi-purpose grease.
- Position the caliper and brake pad assembly over the brake rotor. Be sure to properly install the caliper assembly into the abutments of the steering knuckle or support bracket. Be sure the caliper guide pin bolts, rubber bushings and sleeves are clear of the steering knuckle bosses.
- Fill the master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system.
- Install the wheel and tire assembly.
- Carefully lower the vehicle, then tighten the lug nuts to the proper specifications.
- Depress the brake pedal using short 2 inch (50mm) strokes, in repetitions of 3-4 times until the brake linings are seated and to restore pressure in the system.
- Road test the vehicle and check for proper brake operation.
- Remove the brake caliper shield.
- Detach the lock and clevis pins.
- Disconnect the parking brake cable clip and then the cable from the arm.
- Remove the brake hose banjo bolt and sealing washers.
- Detach the two caliper mounting bolts and the caliper body from the bracket.
- Remove the pins and boots from the caliper assembly.
- Remove the brake pad spring from the caliper body.
- Install the pad spring into the caliper.
- Apply Molykote M77®or equivalent grease in the caliper seal set to the sliding surface of the pins and the inside of the new boots.
- Slide the pin boots into the grooves in the caliper bracket.
- Insert the pins into the caliper bracket.
- Install the brake pad retainers and then the brake pads.
- Align the cutout in the piston with the tab on the backing plate of the inner pad.
- Install the caliper.
- Torque the caliper mounting bolts to 17 ft. lbs. (23 Nm).
- Connect the brake hose to the caliper with the new sealing washers.
- Torque the brake line banjo bolt to 25 ft. lbs. (34 Nm).
- Attach the parking brake cable to the arm on the caliper.
- Securely install the cable clip.
- Install the caliper shield.
- Bleed the air out of the caliper assembly.
- Once all air has been bled from the system, operate the brake pedal several times and then adjust the parking brake.
- Check for leaks.
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.