There are 2 clips on the lower portion of the front brake caliper.. does anyone have a diagram of the caliper layout from a factory manual for a 2004 rmz 250. i need to figure out how each clip locks into place on the lower portion of the caliper

Remove & Replace the Brake Pads

• Loosen lug nuts from the front wheels with the ratchet and socket, but do not remove them.
• Raise the front of the vehicle using the floor jack and secure it with jack stands.
• Remove the lug nuts from the wheels and pull the wheels from the vehicle.
• Look on the rear of the brake caliper and locate the caliper bolts, one upper and one lower.
• Loosen and remove the upper and lower caliper bolts using the ratchet and socket.
• Pull the caliper from the brake assembly, exposing the brake pads, and hang the caliper from a suspension component, using the bungee strap. Do not allow the caliper to hang by its hose, as this may cause damage.
• Grasp the inner and outer brake pads and pull them from the brake assembly. Take note of how they were positioned, as the new brake pads must be placed in the same fashion.
• Place the new brake pads on the brake assembly in the same position the old ones were.
• Position the c-clamp over the caliper so the screw portion is contacting the the caliper's piston--the metal cylindrical object inside the caliper--and the fixed portion of the clamp is contacting the rear of the caliper.
• Tighten the c-clamp until the caliper's piston is fully pressed into the calipers body. The top of the piston is even with the caliper body when fully pressed in.
• Loosen the c-clamp and remove it from the caliper.
• Place the caliper over the new brake pads and hand-tighten the upper and lower caliper bolts.
• Tighten the upper and lower caliper bolts to 26-foot pounds, using the torque wrench and a socket.
• Repeat Steps 4 through 13 for the brake pads on the other side of the vehicle.
• Place the wheels back on the vehicle and hand-tighten the lug nuts.
• Remove the jack stands from under the vehicle and gently lower it to the ground.
• Tighten the lug nuts to 100-foot pounds using the torque wrench and a socket.
• Press and release the brake pedal repeatedly until it feels firm.

IF this helps, don't forget to vote.

Removal & Installation


CAUTION Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle. Remove the front wheels.
3. Remove some brake fluid from the master cylinder reservoir.
4. Disconnect and plug the brake fluid line from the caliper.
5. Remove the brake caliper mounting bolt and guide bolt and remove the caliper from the mount. The brackets can be removed for additional work space.
6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them, if necessary.
   
   

   Fig. Front caliper and related parts
   

To install:

1. Install the brake pads and clips onto the caliper.
2. If the caliper bracket was removed, tighten the bolts to 115 ft. lbs. (155 Nm).
3. Install the caliper on the mounting bracket. Torque the caliper-to-mounting bracket bolts to 33 ft. lbs. (45 Nm).
4. Connect the fluid line to the caliper using new washers. Torque the brake line banjo fitting to 26 ft. lbs. (35 Nm).
   WARNING Be sure the hook end of the flexible brake line is positioned in the anti-rotation cavity.
   
5. Refill the master cylinder reservoir and bleed the brake system.
6. Install the front wheels and lower the vehicle.

Back to Top

SECTION 206-03: Front Disc Brake 1999 Escort/Tracer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 06/06/1998 Front Disc Brake Front Disc Brake System Components
Item Part Number Description 1 1125 Front Disc Brake Rotor 2 2B296 Disc Brake Caliper Locating Pin 3 2B120 Disc Brake Caliper 4 2001 Brake Pads 5 - Copper Washers (2 Req'd) 6 - Banjo Bolt 7 2078 Front Brake Hose 8 2W303 Brake Caliper Bolt- (2 Req'd) 9 2814 Brake Hose Clip The front disc brake system consists of a single-piston front disc brake caliper (2B120) and a ventilated front disc brake rotor (1125). The brake shoes and linings (2001) are held in the front disc brake caliper by two front disc brake caliper locating pins (2B296) and two springs. The inboard brake shoe and lining is equipped with a wear indicator that makes a squealing noise when the brake shoes and linings are worn beyond recommended use.

Removal & Installation Front To Remove:

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the bottom brake caliper pin bolt.
5. Pivot the brake caliper body upward and secure out of the way. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
6. Compress the piston back into the bore using a C-clamp. Figure of brake assembly with caliper raised showing brake pads in mounting bracket
   
   
7. Remove the inboard and outboard brake pads from the brake caliper bracket.

To Install:

1. Install the brake pad retainers and both brake pads into the caliper bracket.
2. Pivot the brake caliper down over the brake pads and into the brake caliper bracket. Insert the lower brake caliper pin bolt and torque bolt to 70 ft-lb. (95 Nm).
3. Reinstall the tire and wheel assembly.
4. Lower the vehicle.
5. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
6. Check the master cylinder level and add fluid as necessary.

Rear To Remove:
Rear disc pads R&I

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the upper caliper mounting bolt.
5. Pivot the caliper down to access the pads.
6. Remove the inboard and outboard pads from the caliper bracket.
7. Remove the brake pad clips from the caliper bracket.
8. Compress the piston back into the bore using a C-clamp and the old inner pad.

To Install:

1. Install new brake clips in the caliper bracket.
2. Install the inboard and outboard pads in the caliper bracket.
3. Pivot the caliper up over the pads.
4. Reinstall the upper mounting bolt and tighten to 32 ft. lbs. (44 Nm).
5. Remove the 2 wheel nuts securing the rotor.
6. Reinstall the tire and wheel assembly.
7. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
8. Check the master cylinder level and add fluid as necessary.

Disc Brake Pads for Suburban 1500 Removal & Installation Front To Remove:
Front caliper mounting bracket

1. Remove the cover on the master cylinder and siphon out 2/3 of the fluid. This step prevents spilling fluid when the piston is pushed back into the caliper bore.
2. Raise and support the vehicle safely.
3. Remove the wheel and tire assembly.
4. Compress the brake piston back into its bore using a C-clamp.
5. Remove the 2 caliper mounting bolts. Lift the caliper off the rotor.
6. Remove the inboard and outboard pad.
7. Remove and discard the anti-rattle clips.

To Install:
Caliper bracket sleeves

1. Thoroughly inspect, clean and lubricate all caliper slide points, bolts and hardware.
2. Install new anti-rattle clips.
3. Position the inboard and outboard pads into the support bracket
4. With the 2 pads in position, place the caliper over the brake rotor and align the holes in the caliper with those of the mounting bracket.
5. Install the caliper mounting bolts through the sleeves in the inboard caliper ears and into the mounting bracket.
6. Tighten the mounting bolts to: 80 lb. ft, (110 Nm).
7. Install the tire and wheel assembly. Lower the vehicle.
8. Add fluid to the master cylinder reservoirs so they are 1/4 in. (6.35mm) from the top.
9. Test the brake pedal by pumping it to obtain a hard pedal. Check the fluid level and add fluid as necessary.

Rear To Remove:

1. Remove 2/3 of the brake fluid from the master cylinder.
2. Raise and safely support the vehicle.
3. Remove the wheel and tire assembly.
4. Remove the brake caliper mounting bolts. Suspend the caliper from the frame with mechanic's wire. Do not allow the caliper to hang from the brake hose.
5. Remove the brake pads from the caliper mounting bracket.
6. Remove and discard the anti-rattle clips.

Rear brake caliper

To Install:

1. Install new anti-rattle clips.
2. Position the brake pads to the caliper mounting bracket.
3. With the 2 pads in position, place the caliper over the brake rotor and align the holes in the caliper with those of the mounting bracket.
4. Install NEW caliper mounting bolts. Tighten to: 30 lb. ft, (40 Nm).
5. Install the wheel and tire assembly.
6. Lower the vehicle.
7. Refill the master cylinder to the proper level with fresh brake fluid. Pump the brake pedal slowly and firmly to seat the brake pads. Burnish the brakes as needed.

caliper bolts are 7 mm Torx head.

SECTION 206-03: Front Disc Brake 2000 Focus Workshop Manual
REMOVAL AND INSTALLATION Brake Pads Removal
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

1. Loosen the wheel nuts.

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel.

1. Detach the brake hose from the support bracket.

1. Detach the outer brake pad retaining clip.

1. NOTE: Pull the caliper outwards to release the piston.
   Detach the caliper.
   1. Remove the bolt covers.
   1. Remove the bolts.

1. CAUTION: Suspend the caliper to prevent load being placed on the brake hose.
   Support the brake calipers.

1. Lift the outer pad retaining clip over the spring retaining lugs.

1. Remove the outer brake pad.

1. Remove the inner brake pad.

Installation

1. CAUTION: If the caliper piston is retracted into the housing, brake fluid will be displaced from the master cylinder.
   Fully retract the caliper piston.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   Install the inner brake pad.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   Install the outer brake pad.

1. Push the outer retaining clip over the spring retaining lugs.

1. Install the caliper.
   1. Install the bolts.
   1. Install the bolt covers.

1. Install the brake hose onto the support bracket.

1. Locate the outer pad retaining clip.

1. Install the wheels.

1. Check the fluid level in the brake fluid reservoir.

Removal & Installation

1. Before servicing the vehicle, refer to the precautions section.
   
2. Remove or disconnect the following:
   
   • Wheels
     
   • Pad retaining clip
     
   • Cap from the bottom caliper bolt
     
   • Lower caliper mounting bolt and swing the caliper up
     
   • Brake pads
     

To install:

1. Press the caliper piston back into the cylinder using tool 49 0221 600C.
   
2. Install or connect the following:
   
   • Outer pad to the mounting support and inner pad to the caliper
     
   • Caliper. Torque the caliper lower mounting bolt to 19–22 ft. lbs. (25–30 Nm). Install the bolt cap.
     
   • Retaining clip
     
   • Wheels
     
3. Pump the brake pedal several times to seat the pads.
   

Press the front caliper piston back into the cylinder—Mazda3

REMOVAL & INSTALLATION

Front Disc Brakes
See Figures 1 through 8
Always replace the brake pads in sets, meaning BOTH front wheels.

1. Raise the front of the vehicle and support it safely using jackstands, then remove the front wheels.
2. Remove the lower caliper lock pin.

The Saturn brake pad replacement procedure states that after removing the lower caliper pin, you can simply pivot the caliper to a vertical position in order to remove the brake pads. This procedure, when attempted on a 1992 SC with ABS, looked as if it would place excessive stress on the brake line. No changes in steering position seemed to alleviate this tension, so a full pivot for pad removal was not attempted. Another option is to remove the upper caliper pin, but not the lower pin, and simply pivot the caliper down for possible access. However, to prevent damage to the brake line you may wish to remove both guide pins and support the caliper assembly from the strut using a coat hanger or length of wire.

1. Pivot the caliper up or down on either guide pin or remove both guide pins and support the caliper from the strut using a coat hanger or length of wire.
2. Remove the 2 brake pads and the pad clips from the caliper support Discard the old pad clips.
3. Check the caliper pins, pin boots and the piston boot for deterioration or damage.

To install:

1. Either by hand or using a C-clamp, bottom the piston all the way into the caliper bore.
2. Carefully lift the inner edge of the piston boot by hand to release any trapped air.
3. Install new pad clips into the caliper support.
4. Install the inner and outer brake pads into the support. If installed, remove the temporary support wire from the caliper.
5. Pivot or position the caliper body on the upper guide pin into position. Compress the boots by hand as the caliper is positioned onto the support.
6. Lubricate the smooth ends of the lock and guide pins with silicone grease, then install the pin and tighten to 27 ft. lbs. (36 Nm). Do not get grease on the pin threads.
7. Repeat the procedure for the opposite side brake pads.

REMOVAL - REAR ROTORS
(1) Raise and support the vehicle
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the caliper adapter bolts (Fig.
61).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPER ADAPTER -
REMOVAL)
(5) Remove the retaining clips and rotor assembly

(Fig. 61).


You can get a factory service manual from Promanuals.net here is a link to the 2004 Dodge Ram Service Manual it was only 20 bucks and very informative.

If you Need Pics/ Illistrations Email @[email protected]


Brake Pads Replacement - Front

Removal Procedure

Caution: Refer to Brake Dust Caution in Service Precautions.

1. Inspect the brake fluid level in the brake master cylinder reservoir.
2. If the brake fluid 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 the brake fluid with appropriate tool to the midway point before proceeding.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Remove the tire and wheel assembly.

1. Compress the front brake caliper piston.

6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper.

1. Remove the lower mounting bolt from the slide pin.
2. Rotate the brake caliper upward until it stops.
3. Remove the outboard brake pad.
4. Remove the inboard brake pad.
5. Remove the brake pad retaining clips from the brake caliper mounting bracket.
6. Remove the brake pad retaining clip from the brake caliper.
7. Remove all foreign material from the brake caliper using denatured alcohol.

Installation Procedure

Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips.

1. Install the brake pad retaining clips to the brake caliper mounting bracket.
2. Install the brake pad retaining clip to the brake caliper.
3. Ensure that the brake pad retaining clip in the brake caliper is properly seated.
4. Install the inboard brake pad.
   
5. Install the outboard brake pad.
6. Rotate the brake caliper down into position.

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the lower brake caliper mounting bolt.

• Tighten the brake caliper mounting bolt to 51 Nm (38 ft. lbs.) .

1. Install the tire and wheel assembly.
2. Lower the vehicle. Refer to Vehicle Lifting.
3. Fill the brake master cylinder reservoir. Caution: Refer to Firm Brake Pedal Caution in Service Precautions.
4. Pump the brake pedal slowly and firmly to seat the brake pads.
5. Burnish the new brake pads.