Cardone 19-B6788 Remanufactured Unloaded Disc Brake Caliper with Bracket Instruction Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Cardone 19-B6788 Remanufactured Unloaded Disc Brake Caliper with Bracket. Please read these instructions thoroughly before beginning any work to ensure safe and correct procedures. This product is designed as a direct replacement part for specific vehicle applications.

2. Safety Information

• Always wear appropriate personal protective equipment, including safety glasses and gloves, when working on vehicle brake systems.
• Ensure the vehicle is securely supported on jack stands before working underneath it. Never rely solely on a jack.
• Brake fluid is corrosive. Avoid contact with skin, eyes, and painted surfaces. In case of contact, flush immediately with water.
• Dispose of old brake fluid and components according to local environmental regulations.
• If you are unsure about any step, consult a qualified automotive technician.

3. Package Contents

Verify that all components are present and undamaged before proceeding with installation. Your package should contain:

• One Cardone 19-B6788 Remanufactured Unloaded Disc Brake Caliper with Bracket.
• New hardware kit (including mounting pins and stainless steel clips where applicable).
• New bleeder screw.
• New banjo bolt (where applicable).
• Plastic cap plug protecting the brake port thread.

Image 3.1: The Cardone 19-B6788 brake caliper shown with its included hardware components, such as mounting pins and clips.

4. Setup and Installation

This section outlines the general steps for installing the brake caliper. Specific vehicle procedures may vary. Refer to your vehicle's service manual for detailed instructions.

4.1. Preparation

1. Park the vehicle on a level surface and engage the parking brake.
2. Loosen the lug nuts on the wheel to be serviced.
3. Raise the vehicle and secure it with jack stands.
4. Remove the wheel.
5. Place a drain pan beneath the caliper to catch any brake fluid.

4.2. Removal of Old Caliper

1. Using a flare nut wrench, carefully disconnect the brake line from the old caliper. Be prepared for brake fluid to leak.
2. Remove the caliper mounting bolts.
3. Carefully slide the old caliper off the brake rotor and set it aside for core return or disposal.
4. Inspect the brake rotor for wear or damage. Replace if necessary.

Image 4.1: A detailed view of the Cardone 19-B6788 remanufactured disc brake caliper, showing the integrated bracket and mounting points.

4.3. Installation of New Caliper

1. Ensure the new caliper's piston is fully retracted. If not, use a caliper compression tool.
2. Install new brake pads into the caliper bracket, ensuring they are seated correctly.
3. Slide the new caliper over the brake rotor and align the mounting holes.
4. Install the new caliper mounting bolts and tighten them to the vehicle manufacturer's specified torque.
5. Connect the brake line to the new caliper using the new banjo bolt and washers (if supplied). Tighten securely, but do not overtighten.

Image 4.2: An angled perspective of the Cardone 19-B6788 caliper, highlighting its overall construction and the bleeder screw location.

4.4. Bleeding the Brake System

After installing the new caliper, it is crucial to bleed the brake system to remove any air that may have entered. Air in the brake lines can lead to a spongy pedal and reduced braking performance.

1. Locate the bleeder screw on the new caliper.
2. Attach a clear hose to the bleeder screw and place the other end into a container partially filled with fresh brake fluid.
3. Have an assistant slowly press the brake pedal down and hold it.
4. While the pedal is held down, open the bleeder screw briefly to allow fluid and air to escape. Close the screw before the pedal reaches the floor.
5. Repeat this process until no air bubbles are visible in the fluid exiting the hose.
6. Maintain the brake fluid level in the master cylinder throughout the bleeding process.
7. Once bleeding is complete, tighten the bleeder screw and remove the hose.

4.5. Final Steps

1. Reinstall the wheel and tighten the lug nuts hand-tight.
2. Lower the vehicle and torque the lug nuts to the manufacturer's specifications.
3. Pump the brake pedal several times to ensure a firm pedal feel before driving.
4. Test drive the vehicle in a safe area at low speeds to confirm proper brake operation.

5. Operating

The Cardone 19-B6788 brake caliper functions as a critical component of your vehicle's hydraulic braking system. When the brake pedal is pressed, hydraulic pressure is applied to the caliper piston, which in turn forces the brake pads against the rotor, creating friction to slow or stop the vehicle. Ensure proper break-in procedures for new brake pads as recommended by the pad manufacturer.

6. Maintenance

Regular inspection and maintenance of your brake system are essential for safety and longevity.

• Brake Fluid Level: Check the brake fluid level in the master cylinder regularly and top off with the correct type of fluid as needed.
• Brake Pad Wear: Inspect brake pads for wear during tire rotations or at least annually. Replace pads when they reach their minimum thickness.
• Caliper Inspection: Periodically check the caliper for leaks, corrosion, or damage. Ensure the bleeder screw cap is in place.
• Brake Rotor Condition: Inspect rotors for excessive wear, scoring, or warping.
• Brake Fluid Flush: Follow your vehicle manufacturer's recommendations for brake fluid flush intervals.

7. Troubleshooting

If you experience any issues after installation, consider the following common problems and solutions:

• Spongy Brake Pedal: This often indicates air in the brake lines. Re-bleed the brake system thoroughly.
• Brake Fluid Leak: Check all brake line connections, banjo bolt, and bleeder screw for proper tightening. Inspect the caliper for any signs of damage.
• Uneven Braking: Ensure both calipers are functioning correctly and that brake pads are installed properly. Check for proper bleeding on both sides.
• Noise (Squealing/Grinding): Squealing can be normal for new pads during break-in or indicate worn pads. Grinding usually means metal-on-metal contact, requiring immediate inspection and replacement of pads and potentially rotors.

8. Specifications

This product is remanufactured, meaning it has been restored to meet or exceed original equipment performance standards. The remanufacturing process reduces energy and raw material consumption significantly compared to manufacturing a new part.

Image 8.1: Illustration demonstrating that remanufacturing a part saves 85% of the energy and raw material required to produce a new part.

9. Warranty

Cardone products are backed by a limited warranty against defects in materials and workmanship. For specific warranty terms, conditions, and claim procedures, please refer to the official Cardone website or contact their customer support directly. Keep your proof of purchase for warranty claims.

10. Support

For technical assistance, product inquiries, or support, please visit the official Cardone website or contact their customer service department. Have your product model number (19-B6788) and purchase information ready when contacting support.