REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
- Raise and safely support the vehicle.
- Remove the wheel and tire assembly, making sure not to damage the bleeder screw fitting during removal. Mark the caliper to ensure that it is reinstalled on the correct knuckle.
- Disconnect the flexible brake hose from the caliper or rotor, depending upon application. Remove the hollow retaining bolt that connects the hose fitting to the caliper or rotor. Remove, then plug the hose assembly from the caliper or rotor.
- For vehicles through 1993, remove the caliper locating pins using Torx® Drive Bit D79P-2100-T40, or equivalent. For 1994-95 vehicles, remove the two rear brake pin retainers.
- Lift the caliper off of the rotor, integral knuckle and anchor plate using a rotating motion.
Do not pry directly against the piston or damage to the piston will likely result.
- Retract the piston fully into the piston bore. Position the caliper assembly above the rotor with the anti-rattle spring under the upper arm of the knuckle. Install the caliper over the rotor with a rotating motion. Make sure the inner and outer shoes are properly positioned and the outer anti-rattle spring is properly positioned. Make sure the clip-on insulators are attached to the brake shoe plate.
- Lubricate the locating pins and the inside of the insulators with silicone grease. For vehicles through 1993, install the locating pins through the caliper insulators and hand-start the threads into the knuckle attaching holes. For 1994-95 vehicles, install the rear brake pin retainers through the caliper holes and into the caliper locating pins, then hand-start.
Make sure the correct caliper assembly, as marked during removal, is installed on the correct knuckle. The caliper bleed screw should be positioned on top of the caliper when assembled on the vehicle.
- Tighten the locating pins to 18-25 ft. lbs. (24-34 Nm) or the rear brake pin retainers to 25 ft. lbs. (34 Nm).
- Remove the plug and install the brake hose on the caliper using a new copper washer on each side of the fitting outlet. Insert the attaching bolt through the washers and fittings, then tighten to 30-40 ft. lbs. (41-54 Nm).
- Bleed the brake system, filling the master cylinder as required; make sure to replace the rubber bleed screw cap after bleeding.
- Install the wheel and tire assembly, then lower the vehicle. Final tighten the lug nuts, in a star pattern, to 85-105 ft. lbs. (115-142 Nm) using a torque wrench, not an impact tool. Pump the brake pedal prior to moving the vehicle to position the brake shoes and linings.
See Figures 5, 6, 7, 8 and 9
- Remove the caliper assembly from the knuckle and rotor. Do not use a screwdriver or similar tool to pry the piston back into the cylinder bore. Use a C-clamp. Remove the outer shoe by pushing the shoe to move the "buttons'' from the caliper housing and slipping down the caliper leg until the clip is disengaged. Remove the inner shoe by pulling it straight out of the piston.
Inner shoe removal force may be as high as 10-20 lbs. (45-90 N)
- If further disassembly is required to service the piston, disconnect the caliper from the hydraulic system, then blow the piston out using air pressure. If the caliper piston is seized, and cannot be forced from the caliper, tap lightly around the piston while applying air pressure.
Do not use a screwdriver or any similar tool to pry the piston out of the bore. It will result in damage to the piston. Cushion the piston's impact against the caliper when blowing it out of the bore by placing rags or a block of wood between the piston and the caliper bridge.
- Remove the dust seal from the caliper, then discard it and replace with a new one during assembly.
- Remove the rubber piston seal from the caliper, then discard it and replace with a new one during assembly.
- When assembling the caliper, examine the piston for surface irregularities or small chips and cracks. Replace the piston if damaged. Be sure to clean the foreign material from the piston surfaces and lubricate with brake fluid before inserting it into the caliper. Always install a new seal and dust boot.
- When installing the piston back into its bore, use a wood block or another flat stock, like an old shoe lining assembly, between the C-clamp and piston. Do not apply the C-clamp directly to the piston surface. This can result in damage to the piston. Be sure the piston is not cocked.
- Be certain the dust boot is tight in the boot groove on the piston and in the caliper.
- To install the inner shoe with its attached three-finger clip into the piston, grab each end of the shoe, making it square with the piston. Push firmly until the shoe clip snaps into the piston. Do not allow the shoe or the clip tangs to cock during installation.
- Install the brake caliper as outlined earlier in this section.