REMOVAL & INSTALLATION
Follow Steps 1 through 4 of the pad removal and installation procedure then disconnect the hydraulic hose. Bleed the system after installing.Delco Type
- Remove the cover on the master cylinder and siphon enough fluid out of the reservoirs to bring the level to 1 /3 full. This Step prevents spilling fluid when the piston is pushed back. Discard the fluid.
- Raise and support the vehicle. Remove the front wheels and tires.
- Push the brake piston back into its bore using a C-clamp.
- Disconnect the brake hose from caliper. Keep a pan handy to catch the brake fluid that spills. Do not reuse the brake fluid.
- Remove the two Allen head bolts which hold the caliper and then lift the caliper off the disc.
- Install rubber bushings on all four caliper ears.
It is essential that new sleeves and rubber bushings be used to ensure the proper function of the sliding caliper design. There is a special Tool recommended No. J-22835 for installing the sleeves.
- Position the sleeves so that the end toward the shoe and lining assemblies is flush with the machined surface of the ear.
- Install the shoe support spring by replacing the single tang end of the spring over the notch in the center of the edge of the shoe. Then press the two tangs at the spring end of the inboard shoe spring over the bottom edge of the shoe so that they engage in the shoe securely.
- Position the inboard shoe and lining assembly (with the spring attached) in the caliper so that the ear end of the shoe and lining is down and the bottom end up at an angle with the spring resting on the piston I.D.. Press down on both ends of the shoe until the shoe is in a flat position, resting on the piston. The spring end of the inboard shoe support spring should be resting on the I.D. of the piston.
The wear sensor of the inboard shoe will be toward the rear of the caliper.
- Position the outboard shoe in the caliper with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cutout. Be sure to note the right and left brake shoes.
- Position the caliper over the rotor, lining up the holes in the caliper ears with the holes in the mounting bracket.
- Reconnect the brake hose inlet fitting. Make sure to install new brass washers, where equipped. Tighten the fitting to 18-30 ft. lbs. (24-40 Nm).
- Install the bolts starting through the inboard caliper sleeves and ears and through the mounting bracket, making sure the ends of the bolts pass under the retaining ears on the inboard shoe. Push the bolts on through to engage the holes in the outboard shoes and the outboard caliper ears at the same time, threading the bolts into the mounting bracket. Torque the bolts to 35 ft. lbs.
- Add fresh brake fluid as necessary to the master cylinder.
- Pump the brake pedal to seat the linings against the rotor.
- Clinch the upper ears of the outboard shoe by position channel lock pliers with one jaw on the top upper ear and one jaw on the notch on the bottom of the shoe opposite the upper ear. After clinching, the ears are to be flat against the caliper housing.
- Bleed the brake system.
- Remove approximately 1 /3 of the brake fluid from the master cylinder. Discard the used brake fluid.
- Jack up your vehicle and support it with jackstands.
- Push the piston back into its bore. This can be done by using a C-clamp.
- Remove the bolt at the caliper support key. Use a brass drift pin to remove the key and spring.
- To install, lubricate the caliper support and support spring, with silicone.
- Install a NEW inboard shoe clip in the steering knuckle or rear support. Install the lower end of the inboard shoe into the groove provided in the steering knuckle or support (against the spring clip). Slide the upper end of the shoe into position. Be sure the clip remains in position.
- Position the outboard shoe in the caliper with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cutout. If assembly is difficult, a C-clamp may be used. Be careful not to mar the lining.
- With both shoes installed, lift up the caliper and rest the bottom edge of the outboard lining on the outer edge of the brake disc to make sure there is no clearance between the tab at the bottom of the outboard shoe and caliper abutment. The outboard shoe should fit tightly in the caliper and should not rattle.
- Position the caliper over the brake disc, guiding the upper caliper groove onto the mating surface of the steering knuckle (or rear support) and lower caliper support. Position the caliper to the lower steering knuckle (or support) sliding surface.
- Place the spring over the caliper support key, install the assembly between the steering knuckle (or rear support) and lower caliper groove. Tap into place until the key retaining screw can be installed, using a brass punch and a light hammer.
- Reconnect the brake hose using new copper gaskets.
- Install the screw and torque to 12-18 ft. lbs. The boss must not fit fully into the circular cutout in the key. Install the wheel and tire and add brake fluid as necessary.
See Figures 1 and 2
See Figures 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12
This procedure requires the use of compressed air to push the piston from the caliper. If a compressor is not available, the vehicle's hydraulic brake pressure may be used to push the piston to its fullest travel once the caliper is removed from the rotor, but before the brake line is disconnected.
- Remove the caliper, clean it and place it on a clean and level work surface.
- If the hose was removed with the caliper, separate the brake hose from the caliper body and discard the copper gasket. Check the brake hose for cracks or deterioration. Replace the hose as necessary.
- Drain the brake fluid from the caliper.
- If applicable, remove drive out the bolt sleeves from the caliper ears, then remove the bushings
- Pad the interior of the caliper with cloth and then apply compressed air to the caliper inlet hose.
- Remove the piston dust boot by prying it out with a drift pin. Use caution when performing this procedure.
- Remove the piston seal from the caliper piston bore using a small piece of wood or plastic. DO NOT use any type of metal tool for this procedure.
- Remove the bleeder valve from the caliper.
Dust boot, piston seal, rubber bushings and sleeves are included in every rebuilding kit. These should be replaced at every caliper rebuild.
- Clean all parts in solvent and dry them completely.
- Examine the mounting bolts for rust or corrosion. Replace them as necessary.
- Examine the piston for scoring, nicks, or worn plating. If any of these conditions are present, replace the piston.
- Check the piston bore. Small defects can be removed with crocus cloth. (Do not use emery cloth.) If the bore cannot be cleaned in this manner, replace the caliper.
- Lubricate the piston bore and the new piston seal with brake fluid. Place the seal in the caliper bore groove.
For Bendix calipers, if available, the use of a piston and boot installation tool such as J-24548 is recommended. The tool is used to hold the boot in position in the caliper and align the piston during installation.
- Lubricate the piston and position the new boot into the groove in the piston so that the fold faces the open end of the piston.
- Place the piston into the caliper bore using caution not to damage the seal. Force the piston to the bottom of the bore.
- Place the dust boot in the caliper counterbore and seat the boot. Make sure that the boot is positioned correctly and evenly. Proper seating of the boot is very important for sealing out contaminants.
- If applicable, lubricate the new sleeves and rubber bushings. Install the bushings in the caliper ears. Install the sleeves so that the end toward the disc pad is flush with the machined surface.
Lubrication of the sleeves and bushings is essential to ensure the proper operation of the sliding caliper design.
- Install the shoe support spring in the piston.
- Install the disc pads in the caliper and remount the caliper in the hub. See pad removal and installation under Disc Brake Caliper.
- Reconnect the brake hose to the steel brake line. Install the retainer clip. Bleed the brakes (see Brake Bleeding).
- Replace the wheels, check the brake fluid level, check the brake pedal travel, and road test the vehicle.