Remove protective paper from the noise suppression gasket and position the properly marked outboard brake shoe assembly onto the caliper (Fig. 7).

Fig. 7 Installing Outboard Shoe Assembly onto Caliper

CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seal on the

sealed for life bushings does not get damaged.

Carefully lower caliper over braking disc and guide holddown spring under machined abutment on knuckle assembly (Fig. 8).

Fig. 8 Guiding Holddown Spring Under Machined

Abutment

Install caliper guide pin bolts and tighten to 24-34 NIm (18-25 ft. lbs.) torque. When installing guide

pin bolts, use extreme caution not to cross thread the guide pin bolts.

Install wheel and tire assembly. Tighten stud nuts in proper sequence until all nuts are torqued to half specification. This is important. Then repeat sequence to full specification.

Remove jackstands or lower hoist. Before moving vehicle be sure it has a firm pedal, pump pedal several times.

Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings.

DISC BRAKE CALIPER DISASSEMBLY

CLEANING AND INSPECTION

Check for piston fluid seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot,(and piston if scored). Refer to procedures titled Disassembling Caliper.

Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Caliper Service.

(1)Remove caliper from braking disc (See Brake Shoe Removal). Hang assembly on a wire hook away from braking disc, so hydraulic fluid cannot get on braking disc (See Fig. 3 in Brake Shoe Removal). Place a small piece of wood between the piston and caliper fingers.

(2)Carefully depress brake pedal to hydraulically push piston out of bore. (Brake pedal will fall away when piston has passed bore opening.) Then prop up the brake pedal to any position below the first inch of pedal travel, this will prevent loss of brake fluid from the master cylinder.

(3)If both front caliper pistons are to be removed, disconnect flexible brake line at frame bracket after removing piston. Plug brake tube and remove piston from opposite caliper. Using the same process as above for the first piston removal.

WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE BE USED TO REMOVE PISTON FROM CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE.

(4) Disconnect brake flexible hose from the caliper. To disassemble, mount caliper assembly in a vise equipped with protective jaws.

CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.

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Clamp caliper in vise (with protective caps on vise jaws).

CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.

Remove dust boot from the brake caliper and discard (Fig. 1).

BRAKES 5 - 41

The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure.

(1) Push out and then pull the inner sleeve from inside of the bushing using your fingers as shown in (Fig. 3).

Fig. 1 Removing Piston Dust Boot

Using a plastic trim stick, work piston seal out of its groove in caliper piston bore (Fig. 2). Discard old seal. Do not use a screwdriver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove.

Fig. 3 Removing Inner Sleeve

(2) Using your fingers collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper assembly (Fig. 4).

Fig. 4 Removing Bushings From Caliper