For 1990-2009 cars

## Brake Caliper Replacement Rear

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
2. Remove the tire and wheel. Refer to Wheel Removal
3. Install two wheel nuts in order to secure the rotor.
4. Complete the following steps if you are removing the caliper (5) from the vehicle:

4.1. | Remove the brake hose bolt attaching the brake hose fitting (4).

4.2. | Remove the following items:

• | The brake hose fitting (4)

• | The copper gaskets

• | Discard the copper gaskets.

• | The brake hose from the caliper

4.3. | Plug the openings in the caliper housing and the hose in order to prevent loss or contamination of the brake fluid.

5. Remove the brake caliper guide pin bolts and discard.
6. Remove the rear brake caliper (3) from the inner and outer pads (2) and mounting plate (1).

If the caliper is not being removed from the vehicle for unit repair, suspend the caliper from the rear suspension using a fabricated wire hook.

7. Remove the inner and outer brake pads (2) from the mounting plate (1) if the following conditions exist:

• | The brake pads are also being replaced.

• | The brake caliper mounting plate is also being removed.

8. Inspect the caliper guide pins for free movement in the caliper mounting plate.
9. Inspect the caliper guide pin boot for proper seating in the retaining groove of the caliper guide pin and the rear caliper mounting plate.
10. Replace the guide pins or guide pin boots if the following conditions exist:

• | Excessive Corrosion

• | Significant Wear

• | Visible Damage

11. Lubricate the inner diameters of the caliper bolt bushings with silicone grease. Also lubricate the caliper bolts with silicone grease.
12. Inspect the inner and outer pads for wear.
13. Inspect the inner and outer pads for maximum taper.

• | Maximum taper of the rear brake pads is 0.15 mm (0.006 in).

• | If the pads are tapered beyond the maximum specification, replace the inner and outer pads as a complete set only.

### Installation Procedure

1. Install the inner and outer pads (2) into the mounting plate (1).
2. Install the rear brake caliper (3) over the brake pads (2) and into the caliper mounting plate (1).

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.

3. Install new brake caliper guide pin bolts.

Tighten
Tighten the brake caliper guide pin bolts to 37 N·m (72 lb ft).

4. Install the following components, if removed:

• | The brake hose

• | The new brake hose fitting gaskets

5. Install the brake hose fitting bolt.

Tighten
Tighten the brake hose fitting bolt to 30 N·m (22 lb ft).

6. Bleed the brake hydraulic system, if the brake hose fitting was removed. Refer to Hydraulic Brake System Bleeding
7. Install tires and wheels. Refer to Wheel Installation
8. Lower the vehicle.
9. While the engine is running, pump the brake pedal slowly and firmly three times in order to seat the inner and outer pads.
10. Check the brake hydraulic system for leaks.

## Brake Caliper Replacement Front

### Removal Procedure

1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
3. Remove the tire and wheel. Refer to Wheel Removal
4. Push the piston into the housing bore in order to provide clearance between the pads and the rotor.

4.1. | Install a large C-clamp (2) over the top of the caliper housing (1) and against the back of the outboard pad.

4.2. | Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough to slide the caliper off the rotor. Do not overtighten the C-clamp. Overtightening the C-clamp will deform the outboard shoe.

5. Complete the following steps if the caliper is being removed from the vehicle for overhaul or replacement:

5.1. | Remove the brake hose bolt attaching the brake hose fitting to the caliper.

5.2. | Remove the following components:

• | The brake hose fitting

• | The copper gaskets

• | Discard the copper gaskets.

• | The brake hose from the caliper

5.3. | Plug the openings in the caliper housing and the hose in order to prevent loss or contamination of the brake fluid.

6. If the caliper is being removed for service of the mounting plate or the brake pads, do not disconnect the inlet fitting.
7. Remove the brake caliper guide pin bolts.
8. Remove the caliper housing from the rotor and the knuckle.

If the caliper is not being removed from the vehicle, suspend the caliper from the front suspension using a fabricated wire hook.

9. Inspect the following parts for corrosion, cuts, nicks or blockage. Replace any damaged parts.

• | The caliper guide pin bolts (6)

• | The caliper guide pin bushings

• | The brake hose fitting

• | If corrosion and/or excessive wear is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion.

### Installation Procedure

1. Lubricate the inner diameters of the caliper bolt bushings (2) with silicone grease.
2. Lubricate the caliper bolts (1). Use silicone grease. Do not lubricate the threads.
3. Inspect the caliper guide pins.

• | The caliper pin should slide through the pin bushings and caliper pin bores using only hand pressure.

• | If greater force is required, remove the caliper pin and the bushings.

4. Inspect the mounting bores (4) for corrosion.

• | If corrosion exists, remove the corrosion using a 1-inch wheel cylinder brush.

• | Clean the mounting bores using clean denatured alcohol.

5. Replace the caliper pin and bushings. Refer to Brake Caliper Overhaul
6. Install the caliper onto the mounting plate and pads.

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.

7. Install the front brake caliper guide pin bolts.

Tighten
Tighten the front brake caliper guide pin bolts to 31 N·m (23 lb ft).

8. If the following components were removed, install them onto the caliper housing using new copper gaskets:

• | The brake hose fitting

• | The brake hose

Tighten
Tighten the front brake hose fitting to 40 N·m (30 lb ft).

9. Install the tire and the wheel. Refer to Wheel Removal
10. Lower the vehicle.

Important: If the brake hose was removed, bleed the caliper. Refer to Hydraulic Brake System Bleeding

11. Fill the master cylinder reservoir to the proper level with clean brake fluid.
12. With engine running, pump brake pedal until firm brake pedal is attained.
13. Check for leaks.