Special Tools

J 23738-A Hand Vacuum Pump.

Warning: Refer to Safety Glasses Warning in the Preface section.

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Adding Fluid to the Brake System Caution in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.





Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

1. Inspect the fluid level in the master cylinder reservoir (1).

•	If the brake fluid level is midway between the maximum fill level and the minimum allowable level, no brake fluid needs to be removed from the master cylinder reservoir (1) before proceeding.

Note: DO NOT completely empty the master cylinder reservoir (1) or remove any brake lines otherwise complete bleeding of the braking system will be necessary.

Note: DO NOT re use the removed fluid.

•	If the brake fluid level is higher than midway between the maximum fill level and the minimum allowable level, syphon the brake fluid to the midway point using a hand vacuum pump (2) before proceeding.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove rear wheels. Refer to Tire and Wheel Removal and Installation.



4. Install 2 wheel nuts (3) in reverse to opposite wheel studs to retain the brake disc to the hub.

Note: Position the ends of the G-clamp against the rear of the brake caliper (1) and against the outboard brake pad (2).

5. Install a large G-clamp over the body of the brake caliper (1).
6. Tighten the G-clamp until the brake caliper piston bottoms out in the brake caliper bore.
7. Remove the G-clamp from the brake caliper (1).




Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.

8. Remove the brake caliper lower guide pin bolt (1) and discard.




Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

Note: DO NOT disconnect the brake hose (1) from the brake caliper (3).

9. Pivot the brake caliper (3) upward and secure with heavy mechanics wire (2), or equivalent.
10. Remove the brake pads (5) from the brake caliper anchor plate (4).
11. Remove the brake pad retainers (6) from the brake caliper anchor plate (4).
12. Clean the brake pad retainer mating surfaces of the brake caliper anchor plate (4).

Note: Inspect the brake caliper guide pins for freedom of movement and the condition of the guide pin boots. This is achieved by moving the guide pins inboard and outboard within the brake caliper anchor plate (4) bores, without disengaging the slides from the boots.

13. Inspect the brake caliper guide pins and boots for the following conditions:

•	Restricted brake caliper guide pin movement

•	Too much brake caliper guide pin play in the brake caliper anchor plate (4)

•	Seized or binding brake caliper guide pins

•	Split or torn boots

14. If any of the conditions listed are found, overhaul or replace the brake caliper (3).

Warning: Refer to Safety Glasses Warning in the Preface section.

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Adding Fluid to the Brake System Caution in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

1. Thoroughly clean both piston to brake pad contact faces as required.



2. Install the brake pad retainers (6) to the brake caliper anchor plate (4).

Note: The brake pads (5) are marked as left hand inner and right hand inner and must only be fitted to their respective positions to optimize brake pad life and performance.

3. Install the brake pads (5) to the brake caliper anchor plate (4).

Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

4. Remove the mechanics wire (2) or equivalent , and rotate the brake caliper (3) into position over the brake pads (5) and to the brake caliper anchor plate (4).

Make sure the brake hose (1) is correctly located in its mounting bracket.

Caution: Refer to Fastener Caution in the Preface section.




5. Install the NEW lower brake caliper guide pin bolt (1) and tighten to 42 N·m (31 lb ft).
6. Remove the 2 wheel nuts retaining the brake disc to the hub.
7. Install the rear wheels. Refer to Tire and Wheel Removal and Installation.
8. Lower the vehicle to the ground.
9. With the engine off, gradually apply the brake pedal approximately 2/3 of its travel distance.
10. Slowly release the brake pedal.
11. Repeat steps 9 and 10 until a firm brake pedal is obtained. This will correctly seat the brake caliper pistons and brake pads.
12. Fill the master cylinder reservoir to the correct level. Refer to Master Cylinder Reservoir Filling.
13. Burnish (bed in) the brake pads and brake discs. Refer to Brake Pad and Rotor Burnishing.