Use a turkey baster or other suitable device to remove the brake fluid from the master cylinder reservoir. Discard of the brake fluid properly. Do not reuse old brake fluid.
Raise and safely support the vehicle on jackstands.
Remove the wheel and tire assemblies.
If the brake pads are being replaced (and the caliper is NOT being overhauled), install a C-clamp on the caliper with the solid frame side of the clamp rests against the back of the caliper and the driving screw end rests against the metal part (center backing plate) of the outboard pad. Tighten the clamp until the caliper moves sufficiently to bottom the piston in the bore, then remove the clamp.
Remove the caliper mounting bolts from the back of the caliper. If the caliper is not being completely removed from the vehicle, detach it from the mounting bracket and support it using a coat hanger or length of wire. DO NOT allow the hose to be stretched, twisted, kinked or otherwise damaged.
If the caliper is being completely removed from the vehicle, place a drip pan below the caliper and disconnect the flexible brake hose-to-caliper banjo-bolt. Discard the pressure fitting washers, then remove the brake caliper from the vehicle and place it on a clean work surface.
To inspect the caliper assembly, perform the following procedures:
Check the inside of the caliper assembly for pitting or scoring. If heavy scoring or pitting is present, caliper replacement is recommended.
Check the mounting bolts and sleeves for signs of corrosion; if necessary, replace the bolts.
If the mounting bolts have signs of corrosion, DO NOT attempt to polish away the corrosion. Instead the bolts must be replaced to assure proper caliper sliding and prevent the possibility of brake drag or locking.
Lubricate and position the caliper bushings and sleeves. Apply silicone lube to the mounting bolts.
With both pads installed, place the caliper over the disc, lining up the hole in the caliper ears with the holes in the mounting bracket.
If the caliper was completely removed, install the flexible hose to the caliper and secure using the banjo bolt and new washers. Make sure that the brake hose is not twisted or kinked, then tighten the bolt to 24-27 ft. Lbs. (31-35 Nm) for all models except Hombre. For Hombre models, tighten to 32 ft. Lbs. (44 Nm).
Carefully insert the mounting bolts through the bracket and caliper (bushing and sleeves), then tighten to 22-25 ft. Lbs. (28-32 Nm) for all models except Hombre. On Hombre models, tighten the bolts to 37 ft. Lbs. (50 Nm).
Pump the brake pedal a few times to seat the linings against the rotors.
Install the wheels, then remove the jackstands and carefully lower the vehicle.
Check and refill the master cylinder reservoirs with brake fluid.
Properly bleed the hydraulic brake system.
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Monday, February 16th, 2009 AT 8:39 PM