Front Brake Caliper Replacement Single Piston
Removal Procedure
- 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.
- Compress the front caliper
piston.
6.1. | Install a large C-clamp over the top of the caliper housing and
against the back of the outboard pad. |
6.2. | Slowly tighten the C-clamp until the piston pushes into the caliper
bore enough to slide the caliper off the rotor |
6.3. | Remove the C-clamp from the caliper. |
- Remove the brake hose-to-caliper
bolt from the caliper.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end in
order to prevent brake fluid loss and contamination.
- Remove and discard the 2 copper brake hose gaskets. These gaskets may
be stuck to the brake caliper and/or the brake hose end.
- Remove the caliper mounting
bolts.
- Remove the caliper.
- Remove the brake linings from the caliper. Refer to
Front Disc Brake Pads Replacement
.
- Remove the caliper mounting bolt sleeves.
- Remove the rubber O-rings and discard.
Installation Procedure
- If reusing the brake caliper pin bolts and retainers, clean the
brake caliper pin bolts and retainers using denatured alcohol or equivalent.
- Dry the brake caliper pin bolts using non-lubricated, filtered
air.
- Apply high temperature
silicone brake lubricant to the brake caliper pin bolts and retainers. DO
NOT apply lubricant to the brake pad hardware.
Important: Lift the inner edge caliper boot next to the piston. Press out any trapped
air. The boot must lay flat below the level of the piston face.
- Install the brake linings to the caliper. Refer to
Front Disc Brake Pads Replacement
.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the caliper and the mounting bolts.
Tighten
Tighten the caliper mounting bolts to 51 N·m (38 lb ft).
- Compress the lining ears
to the caliper.
Notice: Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result.
Important: Install NEW copper brake hose gaskets.
- Install the front brake hose fitting, the 2 new gaskets and the
brake hose fitting bolt.
Tighten
Tighten the front brake hose bolt to 54 N·m (40 lb ft).
Important: If necessary, remove the front brake caliper and file the ends of the
steering knuckle to obtain the proper clearance. If the total clearance exceeds
the specified range, check the steering knuckle and front brake caliper
for damage and replace as necessary.
- Measure the clearance between the caliper and the steering knuckle.
8.1. | Measure each end of the caliper individually. |
8.2. | Add the two measurements together. The total measurement should
be 0.26-0.60 mm (0.010-0.024 in). |
- Install the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Lower the vehicle.
- Fill the master cylinder to the proper level with clean brake
fluid. Refer to
Master Cylinder Reservoir Filling
in Hydraulic Brakes.
- Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding
in Hydraulic Brakes.
- Inspect the hydraulic brake system for brake fluid leaks.
Front Brake Caliper Replacement Dual Piston
Removal Procedure
- 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.
- Install and hand tighten a wheel lug nut in order to retain the
rotor (4WD only).
- Compress the front caliper
piston.
7.1. | Install a large C-clamp over the top of the caliper housing and
against the back of the outboard pad. |
7.2. | Slowly tighten the C-clamp until the piston pushes into the caliper
bore enough to slide the caliper off the rotor |
7.3. | Remove the C-clamp from the caliper. |
- Disconnect the brake hose
from the caliper.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end in
order to prevent brake fluid loss and contamination.
- Remove and discard the 2 copper brake hose gaskets. These gaskets may
be stuck to the brake caliper and/or the brake hose end.
- Remove the caliper guide
pin bolts.
- Remove the caliper from the caliper bracket.
Installation Procedure
- If reusing the brake caliper pin bolts and retainers, clean the
brake caliper pin bolts and retainers using denatured alcohol or equivalent.
- Dry the brake caliper pin bolts using non-lubricated, filtered
air.
- Apply high temperature silicone brake lubricant to the brake caliper
pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware.
- Verify that the brake
pads are in place.
Important: Lift the inner edge of the caliper boots next to the pistons. Press
out any trapped air. The boots must lay flat below the level of the piston
faces.
- Install the caliper over the rotor and into the anchor bracket.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the two
caliper guide pin bolts to the caliper bracket.
Tighten
Tighten the caliper guide pin bolts to 115 N·m (85 lb ft).
Notice: Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result.
Important: Install NEW copper brake hose gaskets.
- Install the front brake hose fitting, the 2 new gaskets and the
brake hose fitting bolt.
Tighten
Tighten the front brake hose bolt to 54 N·m (40 lb ft).
- Install the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Lower the vehicle.
- Fill the master cylinder to the proper level with clean brake
fluid. Refer to
Master Cylinder Reservoir Filling
in Hydraulic Brakes.
- Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding
in Hydraulic Brakes.
- Inspect the hydraulic brake system for brake fluid leaks.