Caliper - Standard Brakes

Caliper -Brake

Special Service tools





Brake Pedal Hold Tool
JDS 9013

Removal

WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.

CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.

CAUTION: The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.

1. Open luggage compartment lid and fit suitable paint work protection equipment.
2. Raise vehicle on a four-post lift.
3. Raise rear of vehicle and support on stands.
4. Remove rear wheel.





5. NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake hose.

Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples.
Connect a bleed tube and container to the calipers. Open bleed nipples.





6. Depress and hold down brake pedal at the specified measurement using the special tool.
Position tool between brake pedal and seat frame.
Turn the tool wheel until the brake pedal is held 60mm down from its released position.





7. Close bleed nipples on both calipers.
Remove bleed tubes and containers.
Tighten front bleed nipple to 4 - 6 Nm.
Tighten rear bleed nipple to 8 - 11 Nm.





8. Disconnect brake hose from rear caliper housing.
Install plugs to caliper and brake hose.





9. Remove caliper housing from caliper carrier.
Remove anti-rattle spring.
Remove dust covers.
Remove guide pins.
Remove housing from carrier.





10. NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston.

Remove and discard brake pads. (See Caution above).





11. Remove caliper carrier from hub carrier.
Remove bolts.
Remove carrier.
12. Clean all mating surfaces and remove brake dust. See Warning above.

Installation





1. Install caliper carrier to hub carrier.
Align carrier to hub carrier.
Install and tighten bolts to 54 - 66 Nm.





2. Make sure piston is fully retracted into caliper housing.
Remove plug from caliper housing.
Retract piston.





3. Install brake pads into caliper housing. (See Caution above).
Remove paper backing from pads to reveal adhesive shim.Install brake pads, insert clip located on back of inner pad into caliper piston.





4. Install caliper housing to caliper carrier.
Align housing to carrier.
Install and tighten guide pins to 25 - 30 Nm
Install dust covers.
Install anti-rattle spring.





5. Connect brake hose to caliper housing.
Remove plugs.
Install and tighten bolt to 30 - 40 Nm.
6. Remove special tool from brake pedal.
7. Fit wheels.
8. Remove stands and lower vehicle.
9. Bleed brake hydraulic system. Hydraulic System