Front Brake Caliper Replacement First Design

1. Remove 2/3 of brake fluid from master cylinder.
2. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



4. Compress the caliper piston into caliper bore to allow the piston enough clearance to pass by the bosses on the brake pads.

•	Install a large C-clamp over top of the caliper housing and against back of the outboard pad.

•	Slowly tighten C-clamp until piston is pushed into caliper bore far enough to slide caliper off rotor.




5. If the caliper is to be removed for repair, remove the bolt attaching the inlet fitting to the caliper, and plug the opening in the caliper and/or pipe to prevent fluid loss and contamination.



6. Remove the caliper pin bolts.
7. Remove the caliper.

1. Install the caliper over the brake pads into the caliper 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.




2. Install the caliper pin bolts.

Tighten
Tighten the caliper pin bolts to 85 N·m (63 lb ft).




3. Install the brake hose inlet fitting to the caliper.

Tighten
Tighten the brake hose fitting bolt to 45 N·m (33 lb ft).

4. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Lower the vehicle.

Front Brake Caliper Replacement Second Design

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 the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.



7. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
9. Remove the C-clamp from the caliper.



10. Remove the brake hose to caliper bolt attaching the brake hose to the brake caliper.
11. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
12. Plug the opening in the brake caliper and pipe to prevent fluid loss and contamination.

Important: Note the location of the caliper pin bolts. The upper caliper pin bolt, has a bushing as part of the assembly. The lower caliper pin bolt, is a solid design pin bolt.




13. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The upper caliper pin, has a bushing as part of the assembly. The lower caliper pin bolt , is a solid design pin bolt .
14. Remove the caliper (2) from the rotor and the caliper bracket (3).
15. Inspect the caliper bolt boots in the caliper bracket for the following conditions:

•

Cuts

•

Tears

•	Deterioration

•	Replace any damaged the caliper bolt boots.

1. If reusing the brake caliper pin bolts and retainers, wipe the old grease from the brake caliper pin bolts and retainers with a clean shop towel.

Important: DO NOT apply lubricant to the brake pad hardware.

2. Apply NIGLUBE® grease to the brake caliper pin bolts. It is not necessary to apply lubricant to the brake pad hardware or the threads of the pin bolts.



3. Install the brake caliper (2) over the brake pads into the brake caliper bracket (3).

Important: The upper caliper pin, has a bushing as part of the assembly. The lower caliper pin, a solid design pin bolt.

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.




4. Install the caliper pin bolts (1). The upper caliper pin bolt, has a bushing as part of the assembly. The lower caliper pin bolt, a solid design pin bolt. Ensure that the bolt boots fit securely around the caliper pin bolts. If the boots are damaged, they must be replaced.

Tighten
Tighten the brake caliper pin bolts to 85 N·m (63 lb ft).

Important: Install NEW copper brake hose gaskets.

5. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.



6. Install the brake hose to caliper bolt to the brake caliper.

Tighten
Tighten the brake hose to caliper bolt to 45 N·m (33 lb ft).

7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 9-10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
11. Remove the 2 wheel lug nuts retaining the rotor to the hub.
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
13. Lower the vehicle.