Brake Caliper Replacement Guide DNT Tools reviewed

Tools and Supplies Needed

Brake caliper
Tool set
Line wrench set
Brake fluid
Needle nose vise grips (optional)
3/8 Fuel line (optional)
Brake caliper lube
Brake cleaner
Vacuum cap assortment



Park your car on level ground with the engine off and the emergency brake on.Raise the car safely using a floor jack and secure with jack stands. Also we will be dealing with brake fluid so be sure to wear protective clothing, eye wear and gloves. This guide picks up after the wheel has been removed and finishes with the tire being reinstalled.



Brake fluid is corrosive and will damage your vehicle’s finish. If this fluid comes in contact with the painted surface quickly wipe it with a clean cloth and then wash the area with soap and water and you should be okay.



There are three reasons to replace the caliper, the first and most obvious is a fluid leak, the second is to prevent a leak due to age and the third is the piston is seized causing irregular braking or pad wear characteristics.


STEP 1: REMOVING THE BRAKE LINE

Once the caliper has been removed from the bracket it is ready for replacement. There are two methods of stopping brake fluid from running out of the master cylinder once the brake line has been removed.



The preferred method is to remove the brake flex hose from the frame brake line and use a rubber cap to plug it off. The reason for this is the master cylinder will drain out of fluid once the caliper line is removed which will cause problems bleeding the system.







Locate the brake line where it connects to the frame mount. Use a line wrench and loosen the fitting. A line wrench is used because these lines can be tight and if you use a regular wrench on them it will round the fitting and cause problems while trying to remove it.







Once the line has been broken loose you can use the regular wrench end and continue removing the fitting which makes the job faster, brake fluid will start to leak out slowly.




After the line is loose brake fluid will be dripping from it metal tube so be ready with a shop towel to catch it.





Now take the rubber cap and install it over the metal brake line to stop the fluid from leaking out. Next use a shop towel to wipe up any excess fluid and then flush with water and soap.




There is an alternative method to stopping the brake fluid from leaking though most professional don't like to use this because it sometimes can break down the internal lining of the hose. Take two pieces of fuel line and cover the jaws of a pair of needle nose vise grips.




Next, adjust the vise grip to gently pinch the rubber brake hose just enough to stop the fluid from flowing. It's important to not over tighten the hold on the rubber line because you don't want to damage it. If the brake line has cracks or is leaking it should be replaced along with the caliper.







Now it is time to remove the brake line from the caliper. Take a mental note or grab your cell phone and take a picture on how the brake line looks going from the frame to the caliper so you an reassemble it in the same manner.



Locate the mounting bolt which is sometimes called a banjo fitting and break it loose with a socket or wrench. A small amount of brake fluid will leak out, reposition the vise grips if fluid keeps leaking out.







There will be two sealing washers that are made of copper or aluminum which are on either side of the brake line bulk head. These washers will need to be replaced and should come with the replacement calipers.



If it is too difficult to loosen the fitting then reinstall the caliper onto the mounting bracket which will hold it while undoing the banjo bolt. Grasp the caliper once the line has been undone because it is heavy and can cause injury if it falls.




Hold the caliper and separate it from the mounting bracket and the rubber flex hose, a small amount of fluid may leak out, now we are ready to match the old caliper to the new unit.