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REMOVAL & INSTALLATION

Pickups
  1. Raise and support the front end on jackstands.
  2. Remove the wheels.
  3. Remove the lower lock pin bolt from the caliper.
  4. Rotate the caliper upward and remove the brake pads and shims.
  5. Remove the master cylinder reservoir cap and remove about half of the fluid from the reservoir.
  6. Using a large C-clamp, depress the caliper piston until it bottoms in its bore.
  7. Install the shims and new pads.
  8. Reposition the caliper and install the lock pin bolt. Torque the bolt to 30 ft. lbs. (41 Nm).
  9. Install the wheels, lower the truck, refill the master cylinder and depress the brake pedal a few times to restore pressure. Bleed the system if required.
MPV

Fig. 1: The bottom end of the inner brake pad is equipped with a pad thickness sensor, which makes a squealing noise to alert you that the pads must be changed

Fig. 2: When removing the disc brake pads, you only have to remove the bottom caliper slide bolts

Fig. 3: After removing the bottom sliding bolt, swing up and support the caliper with a strong piece of wire. Then remove the inner and outer disc brake pads

Fig. 4: Using a brake caliper piston and compressor tool and an old brake pad, push the pistons into the bore. If equipped with dual piston calipers, it may be necessary to alternate the tool back and forth between the pistons (arrows)

Fig. 5: If necessary, remove and clean, or replace, the four anti-rattle clips located in the caliper on the ends of each brake pad

Fig. 6: Before installing the pads and caliper, clean the anti-rattle clips with a brush

Fig. 7: Before installing the sliding caliper bolts, clean them and then lubricate them with brake grease

  1. Raise and support the front end on jackstands.
  2. Remove the wheels.
  3. Remove the lower lock pin bolt from the caliper.
  4. Rotate the caliper upward and remove the brake pads and shims.
  5. Remove the master cylinder reservoir cap and remove about half of the fluid from the reservoir.
  6. Using a large C-clamp and suitable piece of wood, depress the caliper pistons until they bottom in their bores.
  7. Install the shims and new pads.
  8. Reposition the caliper and install the lock pin bolt. Torque the bolt to 69 ft. lbs. (94 Nm).
  9. Install the wheels, lower the vehicle, refill the master cylinder and depress the brake pedal a few times to restore pressure. Bleed the system if required.
Navajo
  1. To avoid fluid overflow when the caliper piston is pressed into the cylinder bore, siphon part of the brake fluid out of the master cylinder reservoir. Discard the removed fluid.
  2. Raise the vehicle and install jackstands. Remove a front wheel and tire assembly.
  3. Place an 8 inch (203mm) C-clamp on the caliper and tighten the clamp to move the piston into the cylinder bore about 1⁄8 (3mm). Avoid clamp contact with the outer pad spring clip. Place the screw end of the clamp below the spring clip. Avoid pad displacement beyond locking tab engagement. Remove the clamp.

    NOTE: Do not use a screwdriver or similar tool to pry piston away from the rotor.

  4. Clean excess dirt from the areas around the pin tabs.
  5. Using a 1⁄4 inch drive socket, 3⁄8 inch deep and a light hammer, tap the upper caliper pin towards the outboard side until the pin tabs pass the spindle face.

    Fig. 8: Knock the caliper mounting pin toward the outboard side

  6. Place one end of a 1/6 inch (11mm) diameter punch against the end of the caliper pin and tap the pin out of the caliper slide groove.
  7. Repeat Steps 5 and 6 to remove the lower pin.
  8. Remove the caliper and hang in out of the way with mechanic's wire. Do not allow the caliper to hang by the brake hose.
  9. Compress the anti-rattle clip and remove the inner brake pad from the caliper. Press each ear of the outer pad away from the caliper and slide the torque buttons out of the retaining notches. Remove the brake pad.

    Fig. 9: Outboard pad mounting

    To install:

  10. Bottom the caliper piston using the C-clamp. Place a piece of wood or the worn out brake pad on the piston before tightening the clamp. Do not attempt to bottom the piston with the outer pad installed. Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated.

    Fig. 10: Anti rattle clip installation

    Fig. 11: Installing the caliper mounting pin

    Fig. 12: Tap the mounting pin on the outboard end until the retention tabs on the side of the pin contact the spindle face

  11. Position the inner pads and anti-rattle clip in the abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position.
  12. Install the outer pad, making sure the torque buttons on the pad spring clip are seated solidly in the matching holes in the caliper.
  13. Install the caliper, using new pins, make sure the mounting surfaces are free of dirt and lubricate the caliper grooves with Disc Brake Caliper Grease. From the outboard side, position the upper pin between the caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face. Tap the pin, on the outboard end with a soft hammer until the retention tabs on the sides of the pin contact the spindle face. Repeat the procedure for the lower pin.

    WARNING
    Never reuse caliper pins. Always install new pins whenever a caliper is removed.

  14. Pump the brake pedal several times to position the pads to the rotor. Fill the master cylinder.
  15. Bleed the brake system if required.
  16. Install the wheel and tire assembly. Torque the lug nuts to 85–115 ft. lbs. (115–156 Nm).
  17. Remove the jackstands and lower the vehicle. Check the brake fluid level and fill as necessary. Check the brakes for proper operation.

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