Front Disc Brake Hardware Replacement 1500 Series

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

1. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Important: Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper.

2. Remove the brake caliper from the caliper bracket. Refer to Front Brake Caliper Replacement .



3. Remove the brake pads from the caliper bracket.
4. Remove the brake pad retainers.



5. Remove the caliper pins, seals, and bushings from the caliper bracket.

1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper pin bushings, seals and pins to the caliper bracket.



3. Install the brake pad retainers to the caliper bracket.
4. Install the brake pads.



5. Install the caliper to the caliper bracket. Refer to Front Brake Caliper Replacement .
6. Slowly apply pressure to the brake pedal until a firm pedal is achieved.
7. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling .
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Front Disc Brake Hardware Replacement 2500 Series

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

1. Inspect the fluid level in the brake master cylinder reservoir.
2. 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.
3. 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.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .



6. Compress the brake caliper pistons.

6.1.	Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad.

6.2.	Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores.

6.3.	Remove the C-clamps from the caliper.




7. Remove the brake caliper guide pin bolts.

Notice: Refer to Brake Caliper Notice in the Preface section.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

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.

8. Remove the brake caliper from the brake caliper bracket and support with heavy mechanics wire or equivalent.



9. Remove the brake caliper guide pin boots (4) from the brake caliper bracket (3)..

1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper guide pin boots (4) to the caliper bracket (3).



3. Install the brake caliper to the caliper bracket.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the brake caliper guide pin bolts.

Tighten
Tighten the bolts to 108 N·m (80 lb ft).

5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
6. Lower the vehicle.
7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
8. Slowly release the brake pedal.
9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained, to properly seat the brake caliper pistons and brake pads.
10. Slowly apply pressure to the brake pedal until a firm brake pedal is achieved.
11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling .