We recommend replacement of the disc brake caliper in axle sets for added safety and reliability
- Raise and safely support the rear of the vehicle.
- Remove the wheel.
- Place a suitable container (to catch the brake fluid) under the brake hose to caliper mounting. Disconnect the brake line at the caliper.
- Remove the brake pads and mounting hardware.
- Remove the upper mounting bolt and remove the caliper.
OVERHAUL AND INSTALLATION
Modify this service procedure by omitting steps, as necessary
- Remove the upper mounting bolt bushing and boot.
- Remove the piston boot snapring and piston boot.
- Use the special service tool or equivalent (mentioned in Pad Removal) to turn the caliper COUNTERCLOCKWISE out of the caliper bore.
- Remove the piston seal from the caliper bore.
Special Service Tool SST 09756-00010, or the equivalent, is required to turn the internal parking brake adjusting nut so that snapring removal is possible
- Position the SST onto the parking brake adjuster nut (bottom of caliper bore) and tighten the nut slightly.
Use the SST or suitable equivalent to ensure that the internally mounted spring will not fly out, causing injury or damage to the caliper bore. DO NOT tighten the adjuster TOO much
- Remove the internal retainer snapring with suitable pliers. Remove the SST.
- Remove the adjuster spring retainer, spring, spring plate and stopper together with the adjusting bolt.
- Remove the strut. Remove the torsion spring from the parking brake crank lever.
- Turn the crank to a position where it will not catch on the stopper pin and remove it from the caliper.
- Remove the crank boot.
- Inspect all parts, service as required.
- Install the parking crank boot into the caliper. Install the parking brake crank and torsion spring.
- Check the clearance of the cable support bracket to caliper. Clearance should be 0.0197-0.0275 inch. (0.5-0.7mm) Adjust the clearance with the cable support mounting bolt.
- Install the strut into the caliper bore. Adjust the needle bearings so that they will not catch on the hole.
- Install a new O-ring on the adjuster bolt. Assemble the stopper, washer, spring and spring case to the adjuster bolt. Use the SST and fully tighten down by hand. Position the marked surface of the stopper upward. Align the notches on the spring case with the notches on the stopper.
- Install the adjuster assembly into the caliper. Install the snapring with the opening in the snapring facing the bleeder hole. Remove the SST. Pull upward on the adjuster assembly and check that it is secured.
- Move the parking brake lever crank by hand to insure that the adjuster bolt moves smoothly.
- Install the piston seal in the caliper bore groove.
- Assemble the piston into the caliper bore by using the SST and slowly screwing in the piston CLOCKWISE. Screw in the piston until it will not descend any further. Align the center of the piston stopper groove with the positioning protrusion on the lower edge of the caliper.
- Install the piston boot. Install the upper mounting bushing and boot.
- Install the brake pads and caliper in the reverse order of removal. Tighten the mounting bolts to 14 ft. lbs. (19 Nm). Connect the parking brake cable. Connect the brake hose.
- Install the wheel and lower the vehicle.
- Fill the master cylinder reservoir. Adjust the parking brake and bleed the brake system. Check for fluid leakage.