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Brake Caliper

Brakes and Traction Control › Disc Brake System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartRight
ManufacturerCHY
OEM part #68003697AA
Price$69.35
PartLeft
ManufacturerCHY
OEM part #68003707AA
Price$69.35
PartRight
ManufacturerCHY
OEM part #68003774AA
Price$61.25
PartLeft
ManufacturerCHY
OEM part #68003778AA
Price$42.60
PartRight
ManufacturerCHY
OEM part #68003697AA
Price$69.35
PartLeft
ManufacturerCHY
OEM part #68003707AA
Price$69.35
PartRight
ManufacturerCHY
OEM part #68003774AA
Price$61.25
PartLeft
ManufacturerCHY
OEM part #68003778AA
Price$42.60
Procedures
Procedures — Disc Brake Caliper - Inspectionreference
△ CAUTION
If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. The bore can be lightly polished with a brake hone to remove very minor surface imperfections (Figure 1). The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).
Procedures — Disc Brake Caliper - Cleaningreference
△ CAUTION
Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal.
CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.
Overhaul — Disc Brake Caliper - Disassembly7 steps
△ CAUTION
Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.
⚠ WARNING
Never attempt to catch the piston as it leaves the bore. This may result in personal injury.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Remove brake shoes from caliper.
  2. Drain brake fluid out of caliper.
  3. Take a piece of wood and pad it with one-inch thickness of shop towels (1). Place this piece in the outboard shoe side of the caliper in front of the piston. This will cushion and protect caliper piston during removal.
  4. Remove caliper piston (2) with short bursts of low pressure compressed air. Direct air through fluid inlet port and ease piston out of bore.
  5. Remove caliper piston dust boot with suitable pry tool (1).
  6. Remove caliper piston seal with wood or plastic tool (1). Do not use metal tools as they will scratch piston bore.
  7. Remove caliper mounting bolt bushings (1) and boots (2).
Overhaul — Disc Brake Caliper - Assembly9 steps
△ CAUTION
Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
Fig. 7
Fig. 7
Fig. 8
Fig. 8
Fig. 9
Fig. 9
Fig. 10
Fig. 10
  1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid.
  2. Lubricate caliper bushings and interior of bushing boots with silicone grease.
  3. Install bushing boots (2) in caliper, then insert bushing into boot and push bushing (1) into place.
  4. Install new piston seal into seal groove (1) with finger.
  5. Install new dust boot on caliper piston and seat boot in piston groove (1).
  6. Press piston (1) into caliper bore by hand, use a turn and push motion to work piston into seal.
  7. Press caliper piston to bottom of bore.
  8. Seat dust boot (3) in caliper with Installer Tool (2) and Tool Handle (1).
  9. Replace caliper bleed screw if removed.
Disc Brake Caliper Adapter - Removal8 steps
△ CAUTION
Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
Fig. 1
Fig. 1
  1. Raise and support the vehicle.
  2. Remove the front wheel and tire assembly.
  3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun.
  4. Bottom the caliper pistons into the caliper by prying the caliper over.
  5. Remove the caliper mounting bolts (3).
  6. Remove the disc brake caliper (4) from the adapter (5).
  7. Remove the inboard and outboard brake pads. Brake Pads - Removal.
  8. Remove the caliper adapter mounting bolts (1).
Disc Brake Caliper - Installation — Rear8 steps
△ CAUTION
Verify brake hose (5) is not twisted or kinked before tightening fitting bolt.
Fig. 1
Fig. 1
  1. Install the brake pads if removed.
  2. Install caliper. Tighten the bolts (6) to 37 Nm (28 ft. lbs.)
  3. Install the brake hose (5) to the caliper with new seal washers and install the brake hose banjo bolt (4) tighten fitting bolt to 31 Nm (23 ft. lbs.).
  4. Remove the prop rod from the vehicle.
  5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.Service and Repair.
  6. Install the wheel and tire assemblies Service and Repair.
  7. Remove the supports and lower the vehicle.
  8. Verify a firm pedal before moving the vehicle.
Disc Brake Caliper - Installation — Front8 steps
△ CAUTION
Verify that the brake hose is not twisted or kinked before tightening the fitting bolt.
Fig. 1
Fig. 1
  1. Install caliper (4) to the caliper adapter (5).
  2. Install caliper mounting bolts (3) and tighten to 37 Nm (28 ft. lbs.).
  3. Install the brake hose banjo bolt (2) and brake hose to the caliper (4) with new seal washers and tighten fitting bolt to 31 Nm (23 ft. lbs.) if removed.
  4. Remove the prop rod from the vehicle.
  5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.Service and Repair.
  6. Install the wheel and tire assemblies Service and Repair.
  7. Remove the supports and lower the vehicle.
  8. Verify a firm pedal before moving the vehicle.
Disc Brake Caliper Adapter - Installation4 steps
Fig. 1
Fig. 1
  1. Install the caliper adapter mounting bolts (1). Tighten the mounting bolts to 135 Nm (100 ft.lbs).
  2. Install the inboard and outboard pads. Brake Pads - Installation.
  3. Install the caliper mounting bolts (3) Disc Brake Caliper - Installation.
  4. Install the tire and wheel assembly. Service and Repair.
Disc Brake Caliper - Removal — Rear6 steps
Fig. 1
Fig. 1
  1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
  2. Raise and support vehicle.
  3. Remove the wheel and tire assembly.
  4. Remove the brake hose banjo bolt (4) if replacing caliper.
  5. Remove the caliper mounting bolts (6).
  6. Remove the caliper from vehicle.
Disc Brake Caliper - Removal — Front6 steps
Fig. 1
Fig. 1
  1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
  2. Raise and support vehicle.
  3. Remove front wheel and tire assembly.
  4. Remove the brake hose banjo bolt (2) if replacing caliper.
  5. Remove the caliper mounting bolts (3).
  6. Remove the caliper (4) from vehicle.
Disc Brake Caliper - Operationreference
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal (Figure 1). Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake shoes do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (Figure 2). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake shoe.
Procedures — Disc Brake Caliper - Inspectionreference
△ CAUTION
If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. The bore can be lightly polished with a brake hone to remove very minor surface imperfections (Figure 1). The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).
Procedures — Disc Brake Caliper - Cleaningreference
△ CAUTION
Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal.
CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.
Overhaul — Disc Brake Caliper - Disassembly7 steps
△ CAUTION
Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.
⚠ WARNING
Never attempt to catch the piston as it leaves the bore. This may result in personal injury.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Remove brake shoes from caliper.
  2. Drain brake fluid out of caliper.
  3. Take a piece of wood and pad it with one-inch thickness of shop towels (1). Place this piece in the outboard shoe side of the caliper in front of the piston. This will cushion and protect caliper piston during removal.
  4. Remove caliper piston (2) with short bursts of low pressure compressed air. Direct air through fluid inlet port and ease piston out of bore.
  5. Remove caliper piston dust boot with suitable pry tool (1).
  6. Remove caliper piston seal with wood or plastic tool (1). Do not use metal tools as they will scratch piston bore.
  7. Remove caliper mounting bolt bushings (1) and boots (2).
Overhaul — Disc Brake Caliper - Assembly9 steps
△ CAUTION
Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
Fig. 7
Fig. 7
Fig. 8
Fig. 8
Fig. 9
Fig. 9
Fig. 10
Fig. 10
  1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid.
  2. Lubricate caliper bushings and interior of bushing boots with silicone grease.
  3. Install bushing boots (2) in caliper, then insert bushing into boot and push bushing (1) into place.
  4. Install new piston seal into seal groove (1) with finger.
  5. Install new dust boot on caliper piston and seat boot in piston groove (1).
  6. Press piston (1) into caliper bore by hand, use a turn and push motion to work piston into seal.
  7. Press caliper piston to bottom of bore.
  8. Seat dust boot (3) in caliper with Installer Tool (2) and Tool Handle (1).
  9. Replace caliper bleed screw if removed.
Disc Brake Caliper Adapter - Removal8 steps
△ CAUTION
Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
Fig. 1
Fig. 1
  1. Raise and support the vehicle.
  2. Remove the front wheel and tire assembly.
  3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun.
  4. Bottom the caliper pistons into the caliper by prying the caliper over.
  5. Remove the caliper mounting bolts (3).
  6. Remove the disc brake caliper (4) from the adapter (5).
  7. Remove the inboard and outboard brake pads. Brake Pads - Removal.
  8. Remove the caliper adapter mounting bolts (1).
Disc Brake Caliper - Installation — Rear8 steps
△ CAUTION
Verify brake hose (5) is not twisted or kinked before tightening fitting bolt.
Fig. 1
Fig. 1
  1. Install the brake pads if removed.
  2. Install caliper. Tighten the bolts (6) to 37 Nm (28 ft. lbs.)
  3. Install the brake hose (5) to the caliper with new seal washers and install the brake hose banjo bolt (4) tighten fitting bolt to 31 Nm (23 ft. lbs.).
  4. Remove the prop rod from the vehicle.
  5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.Service and Repair.
  6. Install the wheel and tire assemblies Service and Repair.
  7. Remove the supports and lower the vehicle.
  8. Verify a firm pedal before moving the vehicle.
Disc Brake Caliper - Installation — Front8 steps
△ CAUTION
Verify that the brake hose is not twisted or kinked before tightening the fitting bolt.
Fig. 1
Fig. 1
  1. Install caliper (4) to the caliper adapter (5).
  2. Install caliper mounting bolts (3) and tighten to 37 Nm (28 ft. lbs.).
  3. Install the brake hose banjo bolt (2) and brake hose to the caliper (4) with new seal washers and tighten fitting bolt to 31 Nm (23 ft. lbs.) if removed.
  4. Remove the prop rod from the vehicle.
  5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.Service and Repair.
  6. Install the wheel and tire assemblies Service and Repair.
  7. Remove the supports and lower the vehicle.
  8. Verify a firm pedal before moving the vehicle.
Disc Brake Caliper Adapter - Installation4 steps
Fig. 1
Fig. 1
  1. Install the caliper adapter mounting bolts (1). Tighten the mounting bolts to 135 Nm (100 ft.lbs).
  2. Install the inboard and outboard pads. Brake Pads - Installation.
  3. Install the caliper mounting bolts (3) Disc Brake Caliper - Installation.
  4. Install the tire and wheel assembly. Service and Repair.
Disc Brake Caliper - Removal — Rear6 steps
Fig. 1
Fig. 1
  1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
  2. Raise and support vehicle.
  3. Remove the wheel and tire assembly.
  4. Remove the brake hose banjo bolt (4) if replacing caliper.
  5. Remove the caliper mounting bolts (6).
  6. Remove the caliper from vehicle.
Disc Brake Caliper - Removal — Front6 steps
Fig. 1
Fig. 1
  1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system.
  2. Raise and support vehicle.
  3. Remove front wheel and tire assembly.
  4. Remove the brake hose banjo bolt (2) if replacing caliper.
  5. Remove the caliper mounting bolts (3).
  6. Remove the caliper (4) from vehicle.
Disc Brake Caliper - Operationreference
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal (Figure 1). Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake shoes do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (Figure 2). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake shoe.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
DISC BRAKE CALIPER
The calipers are a single piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear.
DISC BRAKE CALIPER📷 1
When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. See Fig. 16.
1 - CALIPER 2 - PISTON 3 - PISTON BORE 4 - SEAL 5 - INBOARD SHOE 6 - OUTBOARD SHOE
Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining
against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor.
In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop.
Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake shoes do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution.
The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear.
During brake application, the seal is deflected outward by fluid pressure and piston movement. See Fig. 17. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston.
The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake shoe.
1 - PISTON 2 - CYLINDER BORE 3 - PISTON SEAL BRAKE PRESSURE OFF 4 - CALIPER HOUSING 5 - DUST BOOT 6 - PISTON SEAL BRAKE PRESSURE ON
figure
CALIPER- DISC BRAKE-FRONT📷 1
1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove front wheel and tire assembly. 4. Remove the brake hose banjo bolt (2) if replacing caliper. 5. Remove the caliper mounting bolts (3). 6. Remove the caliper (4) from vehicle.
figure
CALIPER-DISC BRAKE-REAR📷 2
1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the wheel and tire assembly. 4. Remove the brake hose banjo bolt (4) if replacing caliper. 5. Remove the caliper mounting bolts (6). 6. Remove the caliper from vehicle.
figure
figure
DISC BRAKE CALIPER📷 4
1. Remove brake shoes from caliper. 2. Drain brake fluid out of caliper. 3. Take a piece of wood and pad it with one-inch thickness of shop towels (1). Place this piece in the outboard shoe side of the caliper in front of the piston. This will cushion and protect caliper piston during

Removal

4
Remove caliper piston (2) with short bursts of low pressure compressed air. Direct air through fluid inlet
port and ease piston out of bore.
CAUTION
Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.
WARNING
Never attempt to catch the piston as it leaves the bore. This may
result in personal injury.
5
Remove caliper piston dust boot with suitable pry tool (1).
6
Remove caliper piston seal with wood or plastic tool (1). Do not use metal tools as they will scratch
piston bore.
7
Remove caliper mounting bolt bushings (1) and boots (2).
figure
figure
figure
figure
DISC BRAKE CALIPER📷 1
Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.
CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal.
figure
DISC BRAKE CALIPER📷 1
The piston is made from a phenolic resin (plastic material) and should be smooth and clean.
The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing.
CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
The bore can be lightly polished with a brake hone to remove very minor surface imperfections. See Fig. 25.
The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).
1 - SPECIAL HONE 2 - CALIPER 3 - PISTON BORE
figure
DISC BRAKE CALIPER📷 2
1 - BUSHING 2 - BOOT
CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.
1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid. 2. Lubricate caliper bushings and interior of bushing boots with silicone grease. 3. Install bushing boots (2) in caliper, then insert bushing into boot and push bushing (1) into place.
1 - SEAL
GROOVE 2-
figure
figure
SEAL📷 2
4. Install new piston seal into seal groove (1) with finger.
5. Install new dust boot on caliper piston and seat boot in piston groove (1).
1-
PISTON 2-
figure
figure
BOOT📷 1
6. Press piston (1) into caliper bore by hand, use a turn and push motion to work piston into seal. 7. Press caliper piston to bottom of bore.
1 - HANDLE C-4171 2-
INSTALLER C-4842 3 - DUST
figure
BOOT📷 1
8. Seat dust boot (3) in caliper with Installer Tool C-4842 (2) and Tool Handle C-4171 (1).
9. Replace caliper bleed screw if removed.
figure
CALIPER-DISC BRAKE-FRONT📷 1
1. Install caliper (4) to the caliper adapter (5). 2. Coat the caliper mounting bolts (3) with silicone grease. Begin with the bolt closet to the bleeder screws (top), Then install and tighten the bolts to 37 N.m (28 ft. lbs.).
CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt.
3. Install the brake hose banjo bolt (2) and brake hose to the caliper (4) with new seal washers and tighten fitting bolt to 31 N.m (23 ft. lbs.) if removed. 4. Remove the prop rod from the vehicle. 5. Bleed the area of repair for the brake system. If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. . See STANDARD PROCEDURE. 6. Install the wheel and tire assemblies. Refer to STANDARD PROCEDURE . 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle.
figure
CALIPER-DISC BRAKE-REAR📷 1
1. Install the brake pads if removed. 2. Install caliper. Tighten the bolts (6) to 37 N.m (28 ft. lbs.)
CAUTION: Verify brake hose (5) is not twisted or kinked before tightening fitting bolt.
3. Install the brake hose (5) to the caliper with new seal washers and install the brake hose banjo bolt (4) tighten fitting bolt to 31 N.m (23 ft. lbs.). 4. Remove the prop rod from the vehicle. 5. Bleed the area of repair for the brake system. If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. . See STANDARD PROCEDURE. 6. Install the wheel and tire assemblies. Refer to STANDARD PROCEDURE . 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle.
DISC BRAKE CALIPER ADAPTER
figure
DISC BRAKE CALIPER ADAPTER📷 1
1.   Raise and support the vehicle.
  2.   Remove the front wheel and tire assembly.
  3.   Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun.
  4.   Bottom the caliper pistons into the caliper by prying the caliper over.
  5.   Remove the caliper mounting bolts (3).
  6.   Remove the disc brake caliper (4) from the adapter (5).
CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
7. Remove the inboard and outboard brake pads. See REMOVAL. 8. Remove the caliper adapter mounting bolts (1).
figure
DISC BRAKE CALIPER ADAPTER📷 1
1.   Install the caliper adapter mounting bolts (1). Tighten the mounting bolts to 135 N.m (100 ft. lbs).
  2.   Install the inboard and outboard pads. See INSTALLATION.
  3.   Install the caliper mounting bolts (3). See INSTALLATION.
  4.   Install the tire and wheel assembly. Refer to STANDARD PROCEDURE .
ROTORS
figure