Tools Required

SA9151BR - Brake Caliper Release Tool

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Raise vehicle on hoist.
2. Remove wheel corresponding to caliper being removed.
3. Remove brake hose from caliper. Plug openings in caliper and brake hose to avoid fluid loss and contamination.
4. Remove parking brake cable:

4.1.	Slip end of cable off parking brake lever.

4.2.	Remove cable outer housing from cable bracket with SA9151BR (or equivalent).




5. Remove lock pin and guide pin.
6. Remove caliper from caliper support, being careful not to damage pin boots.



7. Remove lock pin and guide pin boots from caliper support. Inspect the following:

7.1.	Lock pin and guide pin boots for deterioration. If damaged, replace.

7.2.	Piston boot for deterioration. If damaged, overhaul the caliper.

7.3.	Lock pin for damage or corrosion. Replace if damaged or corroded (do not attempt to remove corrosion).

1. Make sure caliper piston is bottomed full in its caliper bore.

Important: Remove all rust and corrosion from the caliper brackets and the spring clips when installing brake pads. If installing used brake pads, remove all rust and corrosion from the ends of the brake pads and from the notch. Using a small amount of silicone grease, lubricated both the caliper brackets behind the spring clips and the spring-clip-to-brake-pad interfaces. Make sure the brake pads move freely in the caliper brackets when the brakes are assembled.

2. Make sure brake pads and pad clips are installed in caliper support.



3. Lubricate pin boots with silicon grease.
4. Install lock pin boot into caliper support.

Important: Make sure lock pin boot passes all the way through caliper support.

Important: Use lock pin as a tool to assist installation.

5. Install guide pin boot onto caliper body.



6. Install caliper body onto caliper support.

Important: Be careful not to damage lock pin or guide pin boots.

Important: Compress pin boots by hand as caliper moves into position.

7. Lubricate straight sections (not threads) of lock pin and guide pin with silicone grease.

Notice: Make sure guide and lock pin boots are properly aligned prior to pin installation, or boot damage may occur.

8. Install lock and guide pins.

Tighten
Tighten Hose to: 36 N·m (27 lb ft)




9. Connect brake hose with new washers to caliper.

Tighten
Tighten Hose to: 49 N·m (36 lb ft)

10. Install parking brake cable.
11. Bleed brakes.

Notice: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

12. Position wheel onto hub.
13. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.

Tighten
Tighten Wheel Nuts to: 140 N·m (103 lb ft)

14. Lower vehicle from hoist.

Caution: Prior to operating vehicle, depress brake a few times. If this operation is not carried out, brakes will not operate during initial brake applications and may cause an accident resulting in personal injuries.

15. Prior to operating vehicle, depress brake a few times until brake pads are seated against rotor.