Disc brake caliper — removal and installation
Warning: Dust created by the brake system is harmful to your health. Never blow it out with compressed air and don’t inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use brake system cleaner only.
Note: If replacement is indicated (usually because of fluid leakage), it is recommended that the calipers be replaced, not overhauled. New and factory rebuilt units are available on an exchange basis, which makes this job quite easy. Always replace the calipers in pairs — never replace just one of them.
Removal
1. Loosen the front wheel lug nuts, raise the front of the vehicle and place it securely on jack stands. Remove the wheel.
Note: If the caliper is being removed just to gain access to another component, don’t disconnect the hose.
2. Remove the bolt and disconnect the brake hose from the caliper. Plug the brake hose to keep contaminants out of the brake system and to prevent losing any more brake fluid than is necessary (see illustration). Discard the sealing washers — new ones should be used during installation.
i. 2 Using a piece of rubber hose of the appropriate size, plug the brake line; this will prevent brake fluid from leaking out and dirt and moisture from contaminating the system
3. Remove the caliper mounting bolts while holding the slide pin with an open-end wrench and a socket or boxed end wrench on the bolt (see illustration).
i. 3 Caliper mounting details
1 Brake hose banjo bolt
2 Caliper mounting bolts
3 Caliper mounting bracket bolts
4. With the caliper mounting bolts removed, and the line disconnected, remove the caliper.
Installation
5. Install the caliper by reversing the removal procedure. Remember to replace the sealing washers (gaskets) at the brake hose-to-caliper connection. Tighten the caliper mounting bolts and the brake hose banjo fitting bolt to the torque listed in this Chapter’s Specifications.
6. Bleed the brake circuit (see Brake hydraulic system — bleeding).
Make sure there are no leaks from the hose connections. Test the brakes carefully before returning the vehicle to normal service.