Front Brake Caliper Replacement Dayton-Walther 6500,7500,8500,FM6/FS7

1. Apply the parking brake.
2. Block the wheels.

Important: 

•	Do not completely drain the master cylinder reservoir.

•	Drain the fluid from the brake caliper bleeder valve.

•	Drain the fluid into a suitable container. Discard the fluid.

3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.
4. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle .
5. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation .



6. Remove the brake caliper retainer bolt.
7. Remove the brake caliper retainer and brake caliper spring using a brass punch.



8. Compress the pistons using a C-clamp between the inner brake caliper housing and the outer brake pad.



9. Compress the pistons using screwdrivers to pry between the outer brake caliper housing and the outer brake pad.
10. While compressing the pistons, watch the reservoir for possible brake fluid overflow.
11. Disconnect the brake hose.
12. Cap or tape the brake hose fitting in order to prevent contamination.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

13. Remove the brake caliper.

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

1. Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.



2. Inspect the support rail surfaces on the brake caliper.
3. Inspect the support rail surfaces on the brake caliper mounting plate.
4. Inspect the heat shields. If the heat shields are loose, replace the shields.

1. Clean the support rail surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.
3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper support rail surfaces.



4. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper mounting plate support rail surfaces.



5. Fully compress pistons into the caliper.



6. Install the brake caliper.

Notice: Refer to Installing Hoses without Twists or Bends Notice in the Preface section.

7. Install the brake hose.
8. Loosely assemble the brake hose nut to the brake caliper.

Notice: Refer to Fastener Notice in the Preface section.

9. Loosely assemble the brake hose bracket to the brake caliper.

Tighten

•	Tighten the brake hose nut to 19 N·m (14 lb ft).

•	Tighten the brake hose bracket bolts to 32 N·m (24 lb ft).

Important: 

•	The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

•	Do not reuse the brake caliper retainer bolt .

10. Install a NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt to 450 N·m (332 lb ft).

11. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or equivalent. Refer to Master Cylinder Reservoir Filling .
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

13. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
14. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation .
15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
16. Remove the wheel blocks.

Front Brake Caliper Replacement 6500, 7500, 8500, FM8

1. Apply the parking brake.
2. Block the wheels.

Important: 

•	Do not completely drain the master cylinder reservoir.

•	Drain the fluid from the brake caliper bleeder valve.

•	Drain the fluid into a suitable container. Discard the fluid.

3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.
4. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle .
5. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation .



6. Remove the brake caliper retainer bolt.
7. Remove the brake caliper retainer and brake caliper spring using a brass punch.



8. Compress the pistons using a C-clamp between the inner brake caliper housing and the outer brake pad.



9. Compress the pistons using screwdrivers to pry between the outer brake caliper housing and the outer brake pad.
10. While compressing the pistons, watch the reservoir for possible brake fluid overflow.
11. Disconnect the brake hose.
12. Cap or tape the brake hose fitting in order to prevent contamination.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

13. Remove the brake caliper.

Caution: Avoid taking the following actions when you service wheel brake parts:

•	Do not grind brake linings.

•	Do not sand brake linings.

•	Do not clean wheel brake parts with a dry brush or with compressed air.

Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.
1. Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.



2. Inspect the support rail surfaces on the brake caliper.
3. Inspect the support rail surfaces on the brake caliper mounting plate.
4. Inspect the heat shields. If the heat shields are loose, replace the shields.

1. Clean the support rail surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.
3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper support rail surfaces.



4. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper mounting plate support rail surfaces.



5. Fully compress the pistons into the brake caliper.



6. Install the brake caliper.

Notice: Refer to Installing Hoses without Twists or Bends Notice in the Preface section.

7. Install the brake hose.
8. Loosely assemble the brake hose nut to the brake caliper.

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.

9. Loosely assemble the brake hose bracket to the brake caliper.

Tighten

•	Tighten the brake hose nut to 19 N·m (14 lb ft).

•	Tighten the brake hose bracket bolts to 32 N·m (24 lb ft).

10. Install the wheel speed sensor.

Important: 

•	The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

•	Do not reuse the brake caliper retainer bolt .

11. Install a NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt to 450 N·m (332 lb ft).

12. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or equivalent. Refer to Master Cylinder Reservoir Filling .
13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

14. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
15. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation .
16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
17. Remove the wheel blocks.