AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Disc Brake Pads

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REMOVAL & INSTALLATION




WARNING
To prevent paint damage from brake fluid, be sure to remove part of the brake fluid (don't reuse it) from the master cylinder and keep the master cylinder covered. Do not allow the cylinder to drain too low or air will be pumped into the system.1975-81 Models

EXCEPT PACER

See Figures 1 through 8

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Fig. Fig. 1: Exploded view of the front disc brake componentsall 1975-76 models



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Fig. Fig. 2: Front disc brake component locations1977-78 Matador models



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Fig. Fig. 3: Front disc brake components1977-81 models except Matador and Eagle



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Fig. Fig. 4: Exploded view of the front disc brake components1980-81 Eagle models



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Fig. Fig. 5: Typical front disc brake assembly used on AMC models



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Fig. Fig. 6: Use a ratchet and socket to remove the caliper guide pins ...



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Fig. Fig. 7: ... then remove the caliper from the rotor



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Fig. Fig. 8: Remove the disc pads from the rotor

  1. Raise the front of the car and remove the front wheels.
  2.  
  3. Working on only one brake at a time, remove the caliper guide pins and positioners which attach the caliper to the adapter. Lift the caliper away from the disc.
  4.  
  5. Remove (and discard) the positioners and inner bushings from the guide pins, and the outboard bushings from the caliper.
  6.  
  7. Slide the disc pads out of the caliper, and carefully push the piston back into the bore. Later models have anti-rattle clips. Note their positions before removing them.
  8.  

To install:
  1. Lubricate the new outboard bushings and work them into position from the outboard side of the caliper.
  2.  
  3. Slide the new disc pads into position (outboard pad in the retaining spring) and carefully slide the caliper assembly over the rotor.
  4.  
  5. Lubricate and install the new inner bushings in the caliper. Install the new positioners on the guide pins with the open ends toward the outside.
  6.  
  7. Install the assembled guide pins from the inboard side and press while threading the pin into the adapter. Use extreme care to avoid crossing the threads. Tighten the caliper guide pins to 26 ft. lbs. Be sure that the tabs of the positioners are over the machined surfaces of the caliper.
  8.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Check the brake fluid level and add fluid if necessary. Pump the brake pedal to seat the linings against the disc. Replace the wheels and road test the car.
  2.  

PACER

WARNING
To prevent paint damage from leaking brake fluid, remove about2/3of the brake fluid from the larger reservoir (supplying the front brakes) in the master cylinder, and keep the cylinder reservoir covered. Do not allow the reservoir level to get too low or air will enter the hydraulic system, necessitating bleeding. Do not reuse the removed brake fluid.

  1. Remove the hub caps and loosen the front wheel lug nuts slightly. Firmly apply the parking brake and block the rear wheels.
  2.  
  3. Raise the front of the car and install jackstands beneath the front jacking points or lower control arms. Remove the front wheels.
  4.  
  5. Working on only one caliper at a time, bottom the caliper piston in its bore by carefully inserting a screwdriver between the piston and the inboard shoe and prying back on the piston.
  6.  

Take care not to damage the rubber piston seals. If the piston cannot be bottomed with a screwdriver, a large C-clamp will suffice.

  1. Using a 1 / 4 in. hex key or Allen wrench, remove the caliper support key retaining screw.
  2.  
  3. Remove the caliper support key and support spring using a drift pin and hammer. Lift the caliper assembly off its anchor plate and over the rotor (disc).
  4.  

Do not allow the caliper to hang by its flexible brake hose. Use a piece of heavy wire to suspend the caliper from the coil spring until you are ready to reinstall it.

  1. Remove the inboard brake shoe from the anchor plate. Remove the inboard brake shoe anti-rattle spring from the inboard shoe, noting its position for reassembly.
  2.  
  3. Remove the outboard brake shoe from the caliper, rapping lightly with a hammer, if necessary, to free it from the caliper.
  4.  
  5. Wipe the inside of the caliper free of all accumulated brake pad dust, road dirt and other foreign material with a clean, dry rag.
  6.  

Do not blow the caliper clean with compressed air, as this may dislodge the rubber dust cover.

Check the piston seals for evidence of leakage from the piston bore, and overhaul the caliper if necessary. Clean all rust and dirt from the abutment (sliding), surfaces of the caliper and caliper anchor plate using a wire brush and crocus cloth. Then, lightly grease the sliding surfaces with white grease to ensure that the sliding motion of the caliper is not impaired.

To install:
  1. Install the inboard brake shoe anti-rattle spring on the rear flange of the inboard brake shoe, making sure that the looped section of the clip is facing away from the rotor.
  2.  
  3. Install the assembled inboard brake shoe and anti-rattle spring in the caliper anchor plate, taking care not to dislodge the anti-rattle spring during installation.
  4.  
  5. Install the outboard brake shoe in the caliper, making sure to seat the shoe flange fully into the outboard arms of the caliper.
  6.  
  7. Install the caliper assembly over the rotor and into position in the anchor plate. Exercise extreme care when installing the caliper not to tear or dislodge the piston dust cover on the inboard brake shoe.
  8.  
  9. Align the caliper assembly with the abutment surfaces of the anchor plate and insert the caliper support key and support spring between the abutment surfaces at the rearward end of the caliper and anchor plate. Then, using a hammer and drift pin, drive the caliper support key and spring into position. Install the support key retaining screw and tighten to 15 ft. lbs.
  10.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill the master cylinder reservoir to within 1 / 4 in. (6mm) of the rim. Press the brake pedal firmly several times to seat the shoes.
  2.  
  3. Install the wheels and lower the car. Road test the car after rechecking the fluid level and checking for firm brake pedal.
  4.  

1982-86 Models See Figures 9 and 10

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Fig. Fig. 9: Exploded view of the front disc brake components1982-83 Spirit and Concord models



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Fig. Fig. 10: Exploded view of the front disc brake assembly1982-88 Eagle models

  1. Drain about 1 / 2 the fluid from the master cylinder.
  2.  
  3. Remove the hub cap and loosen the wheel retaining nuts.
  4.  
  5. Raise and support the automobile.
  6.  
  7. Remove the front wheels.
  8.  
  9. Work on one caliper at a time only.
  10.  
  11. Press the caliper piston to the bottom of the piston bore using a screwdriver. If the piston cannot be bottomed using a screwdriver, use a C-clamp.
  12.  
  13. Remove the caliper mounting pins using a 7mm hex or Allen wrench.
  14.  
  15. Lift the caliper assembly out of the anchor plate and off the rotor.
  16.  
  17. Suspend the caliper from the coil spring using a heavy wire. Do not let the brake hose support the weight of the caliper.
  18.  
  19. Remove the outboard brake shoe from the anchor plate while holding the anti-rattle clip against the caliper anchor plate. Note the position of the anti-rattle clip for assembly reference.
  20.  
  21. Remove the inboard brake shoe from the anchor plate and remove the anti-rattle clip.
  22.  


WARNING
The abutment surfaces of the caliper and anchor plate must be clean, smooth, and lightly lubricated with molybdenum disulfide grease before brake shoe and caliper installation. Rust, corrosion, or foreign material on the abutment surfaces will impair the sliding action of the brake shoes in the anchor plate.

To install:
  1. Install the anti-rattle clip on the trailing end of the anchor plate being sure the split end of the clip faces away from the rotor.
  2.  
  3. Install the inboard brake shoe in the caliper anchor late while holding the anti-rattle clip in place.
  4.  
  5. Install the outboard brake shoe in the caliper anchor plate while holding the anti-rattle clip in place.
  6.  
  7. Install the caliper over the rotor and into position in the anchor plate.
  8.  
  9. Install the caliper mounting pins and tighten them to 26 ft. lbs.
  10.  


WARNING
Be very careful to avoid tearing or dislodging the dust boot when installing the caliper. A damaged boot will expose the caliper piston to road splash resulting in corrosion and eventual piston seizure.


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill both master cylinder reservoirs to within 1 / 4 in. (6.3mm) of the rim.
  2.  
  3. Press firmly on the brake pedal several times to seat the brake shoes.
  4.  
  5. Install the wheels and tires and lower the automobile.
  6.  
  7. Check the fluid level in the master cylinder and correct it if necessary.
  8.  


CAUTION
Check for a firm brake pedal and proper brake operation before moving the automobile.

 
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