Rear Brake Caliper Replacement Fixed-Mount 6500, 7500, 8500

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 tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
6. Remove the brake pad retainer spring bolt.
7. Remove the brake pad retainer spring.

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




8. Push back the pistons on one side of the brake caliper.
9. Remove the brake pad.
10. Push back the pistons on the other side of the brake caliper.
11. Remove the remaining brake pad.
12. Remove the brake pipe clip nuts and washers from the rear axle housing studs.
13. Remove the brake pipe bolt and 2 gaskets from the caliper.
14. Cap or tape the brake pipe fitting in order to prevent contamination.




Notice: Do not loosen or remove the four bolts in the brake caliper bridge area. The brake caliper bridge bolts may become loose. If the bridge bolts become loose, replace the brake caliper. Failure to follow these instructions will cause damage to the brake caliper.

15. Remove the brake caliper bolts and washers.
16. Remove the brake caliper from the brake caliper mounting plate.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the brake caliper onto the brake caliper mounting plate.

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

2. Install the brake pipe clips onto the rear axle housing studs.
3. Install the brake pipe clip washers and nuts onto the rear axle housing studs.

Tighten
Tighten the brake pipe clip nuts to 17 N·m (13 lb ft).

4. Install the brake pipe gaskets and bolt.

Tighten
Tighten the brake pipe bolt to 37 N·m (27 lb ft).




5. Install the brake pads.
6. Install the brake pad retainer spring.
7. Install the brake pad retainer spring bolt.

Tighten
Tighten the brake pad retainer spring bolt to 41 N·m (30 lb ft).

8. Fill the master cylinder reservoir with brake fluid. Refer to Master Cylinder Reservoir Filling .
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

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

10. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake pads are seated.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
12. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

13. Remove the wheel blocks.