Brake shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
REMOVAL & INSTALLATION
- To remove the wheel, loosen all the lug nuts at least one full turn, before raising the vehicle.
- Raise and safely support the vehicle.
- Remove the tire and wheel assembly.
- Disconnect and cap the brake hose from the caliper.
- Remove the brake pads.
- Disconnect the parking brake cable from the parking brake lever and remove the return spring.
- Remove the parking brake cable from the parking brake cable bracket. This can be done easily by inserting a 1 / 2 in. (13mm) wrench over the cable end lock tabs and pulling the cable out.
- Remove the two caliper mounting bolts and remove the caliper from the vehicle.
- Install the caliper over the rotor and install the caliper mounting bolts.
- Tighten the mounting bolts to 74 ft. lbs. (100 Nm).
- Install the parking brake cable into the cable mounting bracket.
- Install the return spring and connect the cable end to the parking brake lever.
- Install the brake pads.
- Connect the brake hose to the caliper and tighten the mounting bolt to 33 ft. lbs. (45 Nm).
- Bleed the brake system.
- Install the tire and wheel. Hand-tighten the lug nuts.
- Lower the vehicle, tighten the lug nuts to 100 ft. lbs. (136 Nm).
See Figures 1 and 2
- Raise and support the vehicle. Remove the wheel and tire assembly.
- Remove the caliper.
- Remove the parking brake lever and lever seal nut.
- Inspect the bracket and bridge for cracks or distortion.
- Disassemble the bridge bolts, bracket, and bridge, only if the bridge or bracket is suspected of being cracked or damaged in any way. The caliper can be overhauled without removing the bridge.
- Inspect the piston for scoring, nicks, corrosion, wear and damaged or worn chrome plating. Replace the piston if any defects are found.
- Remove the actuator screw by pressing on the threaded end. Inspect the actuator screw for cracks and thread damage.
- Remove the balance spring, then unsecure the shaft seal and thrust washer from the actuator screw.
- Remove the piston boot with a flat bladed tool, working carefully so that the piston bore is not scratched.
- Remove the piston seal from the caliper bore groove using a piece of pointed wood or plastic. Do not use a metal tool, which will damage the bore. Inspect the caliper bore for nicks, corrosion and so on. Very light wear can be cleaned up with crocus cloth. Use finger pressure to rub the crocus cloth around the circumference of the bore, do not slide it in and out. More extensive wear or corrosion warrants replacement of the part.
- Remove the bleeder screw and cap from the caliper.
- Clean any parts which are to be reused in denatured alcohol. Dry them with compressed or allow to air dry. Don't wipe the parts dry with a cloth, which will leave behind bits of lint.
- Assemble the bracket, bridge and bridge bolts, if they were removed. Tighten the bridge bolts to 74 ft. lbs. (100 Nm).
- Install the bleeder screw, tightening to 110-120 inch lbs. (13-14 Nm)
- Lubricate the new seal (provided in a repair kit), with clean brake fluid. Install the seal in its groove, making sure it is fully seated and not twisted.
- Mount the thrust washer onto the actuator screw, then install the copper side of the thrust washer toward the piston and the grayish side toward the housing.
- Lubricate the shaft seal and insert on the actuator screw.
- Install the new dust boot on the piston. Insert the lubricated screw with the shaft seal and thrust washer into the caliper housing. Install the balancer spring into the housing bore, with the end of the spring in recess at the bottom of the bore.
- Lubricate the bore of the caliper with clean brake fluid and insert the piston into its bore. Make sure the piston is well lubricated before insertion. Position the boot in the caliper housing and seat with a seal driver of the appropriate size, or tool No. J-36623.
- Turn the actuator screw as necessary to allow the piston assembly to move to the bottom of the caliper bore. Lubricate the lever seal and install over the end of the actuator screw. The rubber sealing bead over the lever seal should be against the parking lever, and the copper end should be against the housing.
- Hold the parking lever back against the stop on the caliper housing while tightening the nut. This will prevent any accidental application of the parking brake mechanism.
- Insert the lever and nut, the hex hole in the lever must engage the hex hole in the actuator screw. Tighten the nut to 35 ft. lbs. (47 Nm).
- Seat the caliper boot to the counterbore in the housing using tool No. J-36622 and J-36623.
- Install the pads and the caliper, then bleed the brakes.
- Lower the vehicle.