Removal Procedure
Caution: Refer to Brake Dust Caution in the Preface section.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.
- Inspect the fluid level in the brake master
cylinder reservoir.
- If the brake fluid level is midway between the maximum-full point and
the minimum allowable level, no brake fluid needs to be removed from the reservoir
before proceeding.
- If the brake fluid level is higher than midway between the maximum-full
point and the minimum allowable level, remove brake fluid to the midway point before
proceeding.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Inspect the caliper operation. Refer to
Brake Caliper Inspection
.
- Place a C-clamp as shown. Slowly bottom the pistons of the caliper. It
may be necessary to reposition the C-clamp to allow both of the pistons to bottom
into the caliper bores.
Notice: 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.
- Remove the caliper from the mounting bracket and support the caliper with heavy
mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose
from the caliper. Refer to
Rear Brake Caliper Replacement
.
- Inspect the caliper assembly. Refer to
Brake Caliper Inspection
.
- Remove
the brake pads from the brake caliper bracket.
- Remove and discard the anti-rattle clips from the brake caliper mounting
bracket.
Installation Procedure
- Install
the anti-rattle clips to the brake caliper bracket.
Important: Proper orientation of the brake pads is critical
for proper pad wear.
- If working on a 2WD 1500 series utility, install the inboard rear
pad to the brake caliper bracket with the longer pad end chamfer facing
down. For all other utilities, install the brake pads to the brake caliper.
- Install the brake pads to the brake caliper bracket.
- Install the brake caliper to the mounting bracket using NEW bolts. Refer
to
Rear Brake Caliper Replacement
.
- Install the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Lower the vehicle.
- With the engine OFF, gradually apply the brake pedal to approximately 2/3
of its travel distance.
- Slowly release the brake pedal.
- Wait 15 seconds, then repeat steps 7- 8 until a firm
pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
- Fill the master cylinder reservoir to the proper level with clean brake
fluid. Refer to
Master Cylinder Reservoir Filling
in Hydraulic Brakes.
- Burnish the brakes pads and rotors as necessary. Refer to
Brake Pad and Rotor Burnishing
.