Orlando

Rear Brake Calliper Replacement — with Dampener

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .



6. Remove the brake hose-to-calliper bolt (2) from the brake calliper.
7. Remove the brake hose (1) from the brake calliper.
8. Remove and discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake calliper and/or the brake hose end.
9. Cap or plug the opening in the brake calliper and the brake hose to prevent fluid loss and contamination.



10. Remove the upper brake calliper pin bolt (1).
11. Remove the brake calliper vibration damper (3).



12. Remove the handbrake cable from the rear handbrake lever (1).
13. Remove the brake caliper from the brake caliper bracket.

1. Inspect the calliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Calliper Hardware Replacement .



2. Install the brake calliper to the brake calliper bracket.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the lower brake calliper pin bolt (1) and tighten to 28 N·m (20 lb ft).
4. Install the brake calliper vibration damper (3) and tighten to 28 N·m (20 lb ft).



5. Install the handbrake cable to the rear handbrake lever (1).



6. Remove the caps or plugs from the brake calliper opening and the brake hose.

Note: DO NOT reuse the copper brake hose gaskets.

7. Install NEW copper brake hose gaskets (3) to the brake hose-to-calliper bolt (2) and to the brake hose.
8. Install the brake hose and the brake hose-to-calliper bolt to the brake calliper and tighten the bolt to 40 N·m (30 lb ft).
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake calliper pistons and brake pads.
13. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
14. Lower the vehicle.
15. Apply and release the park brake lever 4 times.