Front Brake Caliper Replacement Base and GT

Special Tools

J 23738-A Hand Vacuum Pump.

Warning: Refer to Safety Glasses Warning in the Preface section.

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

Warning: Refer to Brake Fluid Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Adding Fluid to the Brake System Caution in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.





Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

1. Inspect the fluid level in the master cylinder reservoir (1).

•	If the brake fluid level is midway between the maximum fill level and the minimum allowable level, no brake fluid needs to be removed from the master cylinder reservoir (1) before proceeding.

Note: DO NOT completely empty the master cylinder reservoir (1) or remove any brake lines otherwise complete bleeding of the braking system will be necessary.

Note: DO NOT re use the removed fluid.

•	If the brake fluid level is higher than midway between the maximum fill level and the minimum allowable level, using a hand vacuum pump (2), syphon the brake fluid to the midway point before proceeding.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the front wheels. Refer to Tire and Wheel Removal and Installation.



4. Install 2 wheel nuts (1) in reverse to opposite wheel studs to retain the brake disc to the hub.

Note: Position the ends of the G-clamps against the rear of the brake caliper (2) and against the outboard brake pad (3).

5. Install large G-clamps over the body of the brake caliper (2).
6. Tighten the G-clamps evenly until the brake caliper pistons bottom in each brake caliper bore.
7. Remove the G-clamps from the brake caliper (2).
8. Place a clean suitable container under the brake caliper assembly.



9. Remove the brake hose to brake caliper banjo retaining bolt (4).

Note:  Install a rubber cap or plug on the exposed brake hose end in order to prevent fluid loss and contamination.

10. Separate the brake hose to brake caliper banjo retaining bolt (4) from the brake hose (2).

Note: Copper brake hose sealing washers become work hardened due to the heat generated with brake applications and will not reseal. Install NEW copper brake hose sealing washers (3) whenever the brake hose to brake caliper banjo retaining bolt (4) is removed.

11. Remove and discard the 2 copper brake hose sealing washers (3). The copper brake hose sealing washers (4) may be stuck to the brake caliper (1) and/or the brake hose (2).

Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.

12. Remove the brake caliper anchor plate to knuckle retaining bolts (5) and discard.
13. Remove the brake caliper assembly (1) from the front hub assembly.

Warning: Refer to Safety Glasses Warning in the Preface section.

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

Warning: Refer to Brake Fluid Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Adding Fluid to the Brake System Caution in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

1. Clean the front brake caliper anchor plate mounting surfaces to the front steering knuckle.
2. Check the serviceability of the brake pads. Refer to Brake Pad Inspection.

Note: The brake pads are marked as inner and outer only. Failure to install the brake pads in their correct position will cause the brake pads not to seat correctly in the brake caliper.

3. Install the existing or NEW brake pads as required.
4. Press the inner brake pad by using a suitable tool to make sure the brake caliper pistons bottom in each brake caliper bore.
5. Position the front brake caliper assembly over the front brake disc.

Caution: Refer to Fastener Caution in the Preface section.




6. Install the NEW front brake caliper anchor plate to front steering knuckle retaining bolts (5) and tighten to 60 N·m +120° (44 lb ft +120°).

Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

Note: Install NEW copper brake hose sealing washers (3).

7. Install the front brake hose (2) to brake caliper banjo retaining bolt (4) and NEW copper brake hose sealing washers (3) to the front brake caliper (1). Tighten the banjo bolt to 35 N·m (25 lb ft).
8. Bleed the braking system. Refer to Hydraulic Brake System Bleeding.
9. Remove the 2 wheel nuts retaining the brake disc to the hub.
10. Install the front wheels. Refer to Tire and Wheel Removal and Installation.
11. Lower the vehicle to the ground.
12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
13. Slowly release the brake pedal.
14. Repeat steps 12 and 13 until a firm brake pedal is obtained. This will correctly seat the brake caliper pistons and brake pads.
15. Fill the master cylinder reservoir to the correct level. Refer to Master Cylinder Reservoir Filling.
16. Burnish (bed in) the brake pads and brake discs if required. Refer to Brake Pad and Rotor Burnishing.