Parts Catalog Accessories Catalog Tech Info Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Brake Caliper Replacement
 
Bookmark and Share

Pelican Technical Article:

Brake Caliper Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$250

Talent:

****

Tools:

Socket set 13mm, flathead screwdriver, 11mm 12mm line wrenches, floor jack, two jack stands, lug wrench, two wheel chocks, safety glasses, torque wrench

Applicable Models:

BMW X5 (2000-06)

Parts Required:

Brake caliper, brake fluid, brake hose

Hot Tip:

Bleed entire brake system

Performance Gain:

Great brake feel

Complementary Modification:

Replace brake pads and hoses at same time.

As you apply your brakes a piston in your master cylinder creates brake fluid pressure. This pressure travels through brake lines and brake hoses to the caliper. The brake fluid pushes caliper pistons into the brake pad, which in turn clamps against the brake rotor. This is what stops your vehicle.

The brake caliper is responsible for providing the clamping force needed on the brake pads to slow your vehicle down. The brake caliper can leak fluid as it ages from the piston seal and also becomes corroded or restricted resulting in poor brake performance. If a brake caliper is not performing at 100%, you may notice a slight pull to one side when braking. If you are experiencing an issue like this, jack the front of your vehicle. Then apply and release the brake. One of the wheels may hang or release slowly. That is the problem caliper.

You can service each brake caliper individually or both at the same time. I recommend replacing in pairs to maintain an even brake feel. If one caliper is failing, the other will not be far behind.

Remember, your car may have been serviced before and parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve as they grow older. If something seems different, let us know and share your info to help other users. Questions or want to add to the article? Leave a comment below.

Lift and support the axle of the vehicle you are replacing the brake calipers on. See our tech article on jacking up your vehicle.

There are two ways to reduce the amount of brake fluid loss when replacing your brake caliper. One way is to clamp the hose with a hose clamp tool to prevent the fluid from leaking. This method could lead to a damaged hose if done incorrectly.

I prefer to use the second method.
Figure 1

I prefer to use the second method. Depress brake pedal half way and hold it in place with a stick or brake pedal depressing tool (red arrow). This will keep fluid in the master cylinder from leaking.

Using a flathead screwdriver, remove the brake caliper anti-rattle spring (green arrow) by prying it out while securing it with your hand.
Figure 2

Using a flathead screwdriver, remove the brake caliper anti-rattle spring (green arrow) by prying it out while securing it with your hand. The spring can pop off and go flying. Be sure to hold it steady.

Open the brake caliper bleeder cover (red arrow) and remove the pad wear sensor (yellow arrow) wire from the mount.
Figure 3

Open the brake caliper bleeder cover (red arrow) and remove the pad wear sensor (yellow arrow) wire from the mount. Pull the brake pad wear sensor (green arrow) out of the brake pad from the left side brake pad. Be very careful, as the sensor tends to break when removed. I like to use a pair of needle nose pliers to pull the sensor out.

Using a flathead screwdriver, slowly press the brake caliper piston in.
Figure 4

Using a flathead screwdriver, slowly press the brake caliper piston in. This allows the brake caliper to be pulled off the brake rotor easily. I like to pry between the outer brake pad and the brake rotor. This way there is less chance of damaging the caliper piston.

Working at the brake caliper using a 12mm line wrench.
Figure 5

Working at the brake caliper using a 12mm line wrench. Loosen the brake hose (red arrow). Do not remove it. You will unscrew the hose from the caliper later. You can use a regular 13mm open-end wrench. However, you risk damaging the hex on the brake line.

Remove the rubber plugs from the brake caliper mounting fasteners (green arrows).
Figure 6

Remove the rubber plugs from the brake caliper mounting fasteners (green arrows).

Next, using a 7mm Allen bit, remove the brake caliper mounting fasteners (green arrows).
Figure 7

Next, using a 7mm Allen bit, remove the brake caliper mounting fasteners (green arrows).

Remove the brake caliper from the mounting bracket and unscrew the brake hose from the caliper.
Figure 8

Remove the brake caliper from the mounting bracket and unscrew the brake hose from the caliper. If you want to replace the brake hose, loosen the 11mm brake line nut using a line wrench. Then unscrew the metal brake line from the hose. Then remove the hose from the mounting bracket and install a new one in place of it. Screw the new caliper into the brake hose and then install the caliper in the mounting bracket. Tighten the caliper mounting fasteners and install the plugs and the anti-rattle clip. Then tighten the caliper brake hose. Clip the brake pad wear sensor-wiring harness back onto the brake hose, if equipped. Bleed the brakes. See our tech article on bleeding the brakes.

Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Privacy Statement]
 [Contact Us] [About Us] [Shipping] [Map to our Location] [Careers]

Copyright © Pelican Parts Inc.

Page last updated: Fri 12/9/2016 02:43:24 AM