DESCRIPTION & OPERATION
Hydraulic system pressure differential is controlled and monitored by combination valve, located below master cylinder (attached to ABS modulator on Camaro and Firebird). Combination valve performs the following functions
- Limits amount of pressure applied to rear brakes to allow most pressure to be applied to front brakes.
- Transfers hydraulic pressure to front brakes if pressure loss occurs in rear brakes and vice versa.
- Closes contacts in pressure differential switch to turn on BRAKE warning indicator light.
- On Fleetwood, Caprice and Roadmaster, metering valve portion of combination valve prevents hydraulic pressure from being applied to front brakes until rear brakeline pressure has overcome rear brake shoe return spring tension, and brake shoe-to-drum clearance has been taken up.
Disc brakes are continually self-adjusting. Caliper piston seals are designed to retract pistons enough to allow brake lining to lightly brush rotor. Sliding caliper design compensates for lining wear.
BRAKE WARNING INDICATOR INOPERATIVE
See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
BLEEDING BRAKE SYSTEM
| CAUTION | DO NOT reuse brake fluid. Use only new, clean DOT 3 brake fluid. DO NOT use silicone brake fluid. Check brake fluid level frequently during bleeding procedure. |
MANUAL BLEEDING
Note. On Fleetwood, bleed ABS modulator if master cylinder reservoir fluid level was low during traction control mode or if ABS modulator was removed and installed.
ABS Modulator (Fleetwood)
Fill brake fluid reservoir. Keep reservoir at least half full during procedure. Attach clear hose to bleeder valve on ABS modulator. (Scheme 1) Submerge hose end in clear container partially filled with brake fluid. Open bleeder valve. Allow fluid to drain until air bubbles cannot be seen in fluid. Close bleeder valve. Remove hose.
Scheme 1
Note. For brake system bleeding on Camaro and Firebird, see appropriate ANTI-LOCK BRAKE SYSTEM article.
Brake System (Caprice, Fleetwood and Roadmaster)
- Deplete vacuum reserve from power brake booster by depressing brake pedal several times with engine off. Fill master cylinder and keep at least half full during bleeding procedure. If master cylinder is not known or suspected to have air in bore, go to step 4). If master cylinder is known or suspected to have air in bore, go to next step.
- Disconnect forward brakeline fitting at master cylinder. Allow fluid to flow from fitting. Tighten fitting to specification. See TORQUE SPECIFICATIONS table at the end of this article. Have an assistant depress brake pedal slowly and hold. Loosen forward fitting. Tighten fitting while pedal is still at floor. Release brake pedal slowly. Wait 15 seconds.
- Repeat step 2) until fluid is clear and free of air bubbles. Repeat procedure at other (rearmost) brakeline fitting on master cylinder. Master cylinder is now bled. If wheel cylinders/calipers are not known or suspected to have air in them, it is not necessary to bleed them.
- If wheel cylinders/calipers are known or suspected to have air in them, raise and support vehicle. Remove bleeder valve cap from first bleeder valve to be serviced. See BRAKELINE BLEEDING SEQUENCE table. Place wrench over bleeder valve.
- Attach clear vinyl bleeder hose onto bleeder valve. Place other end of hose in clear container partially filled with clean brake fluid. Submerge end of hose in fluid. Open bleeder valve 1-2 turns. Slowly depress brake pedal to floor.
- Close bleeder valve. Release pedal. Pump pedal several times to push air toward wheel cylinder/caliper. Wait 15 seconds and repeat procedure until fluid is clear and free of air bubbles. Repeat procedure on remaining bleeder valves.
| Application | Sequence |
|---|---|
| Caprice, Fleetwood & Roadmaster | RR, LR, RF, LF |
BRAKELINE BLEEDING SEQUENCE
PRESSURE BLEEDING
Note. For brake system bleeding on Camaro and Firebird, see appropriate ANTI-LOCK BRAKE SYSTEM article.
- Clean master cylinder reservoir cap and surrounding area. Remove cap. With pressure bleeder tank at least 1/2 full of brake fluid and charged with 10-30 psi (.70-2.10 kg/cm 2 ) air pressure, connect tank to master cylinder using proper adapter(s).
- On vehicles with rear disc brakes, go to next step. On vehicles with rear drum brakes, a manual override is necessary to permit brake fluid flow to front wheels when pressure bleeding. To enable override, attach Combination Valve Pressure Bleeder Adaptor (J-39177) to combination valve.
- Raise and support vehicle. Attach bleeder hose to first bleeder valve to be serviced. See BRAKELINE BLEEDING SEQUENCE table under MANUAL BLEEDING. Place other end of hose in clear container partially filled with clean brake fluid. Submerge end of hose in fluid.
- Open release valve on pressure bleeder. Open first bleeder valve to be serviced. When fluid flowing into container is clear and free of bubbles, close bleeder valve securely. Open and close each remaining bleeder valve in turn to finish bleeding system. Disconnect pressure tank from master cylinder. Remove adaptor from combination valve. Check brake fluid level. Fill as necessary.
BRAKE PEDAL HEIGHT & FREE PLAY
Information is not available from manufacturer.
BRAKE PEDAL TRAVEL
Note. Brake pedal travel is not adjustable. Following procedure determines if brake pedal travel is as specified. Most low brake pedal problems are caused by air in hydraulic system. Bleed hydraulic system before performing procedure. See BLEEDING BRAKE SYSTEM.
Caprice, Fleetwood and Roadmaster
- With engine off, pump brake pedal until all vacuum reserve is exhausted from power brake booster. A definite change in pedal feel will occur. Install Brake Pedal Effort Gauge (J-28662) onto brake pedal. Hook end of tape measure over top of brake pedal. Measure and record distance to rim of steering wheel.
- Apply 100 lbs. (45 kg) of force to brake pedal. Measure and record distance to rim of steering wheel again. Difference between measured values is brake pedal travel.
- If brake pedal travel exceeds specification, adjust rear brake shoes. See BRAKE PEDAL TRAVEL SPECIFICATIONS table. See REAR BRAKE SHOES under ADJUSTMENTS. Recheck brake pedal travel. If brake pedal travel still exceeds specification, repair brake system.
Camaro and Firebird
- Install Brake Pedal Effort Gauge (J-28662) onto brake pedal. Hook end of tape measure over top of brake pedal. Measure and record distance to rim of steering wheel.
- Block drive wheels. Run engine at idle. Shift transmission into Neutral. Apply 100 lbs. (45 kg) of force to brake pedal. Measure and record distance to rim of steering wheel again. Difference between measured values is brake pedal travel.
- If brake pedal travel exceeds specification, adjust rear brake shoes. See BRAKE PEDAL TRAVEL SPECIFICATIONS table. See REAR BRAKE SHOES under ADJUSTMENTS. Recheck brake pedal travel. If brake pedal travel still exceeds specification, repair brake hydraulic system.
| Application | In. (mm) |
|---|---|
| Caprice, Fleetwood and Roadmaster | 2.24 (57.0) |
| Camaro and Firebird | 2.00-3.50 (51.0-89.0) |
BRAKE PEDAL TRAVEL SPECIFICATIONS
REAR BRAKE SHOES
Note. Adjustment is only required if shoes have been serviced or length of adjusting screw has been changed.
- Release parking brake. Raise and support vehicle. Remove wheels and drums. Ensure parking brake cable, linkage and secondary (rear) shoe levers have free movement.
- If using Brake Drum Gauge (J-21177), go to next step. If not using Brake Drum Gauge (J-21177), turn adjuster wheel until diameter of brake shoes is .050" (1.27 mm) less than inside diameter of brake drum. Go to step 4).
- Measure inside diameter of brake drum using inside caliper portion of Brake Drum Gauge (J-21177). Turn adjuster wheel until brake shoes contact outside caliper portion of brake drum gauge.
- Install drums and wheels. Tighten wheel lug nuts to specification. See TORQUE SPECIFICATIONS table at the end of this article. Lower vehicle. Drive vehicle, making several alternate forward and backward stops, applying brakes firmly.
Preliminary Information (Camaro and Firebird)
- Adjustment is normally required only if caliper has been disassembled or pads have been replaced. Ensure brake pads are NEW or parallel to within.006" (.15 mm) thickness. Adjustment will not be accurate if pads are heavily tapered.
- Turning adjusting screw clockwise increases free play. (Scheme 2) Turning adjusting screw counterclockwise decreases free play. Adjustment will not correct a condition such as levers not returning to their stops.
Adjustment (Camaro and Firebird)
- Disconnect cable end from parking brake lever on caliper. (Scheme 2) Remove lever return spring. Have an assistant apply and hold light pressure on brake pedal (enough to stop rotor from turning by hand). This takes up clearances and ensures components are aligned.
- Apply light hand pressure to parking brake lever. Check free play between lever and caliper stop. If free play is not.024-.028" (.60 -.70 mm), go to next step. If free play is.024-.028" (.60 -.70 mm), parking brake cable is adjusted. Install lever return spring. Reconnect parking brake cable.
- Remove adjusting screw. Clean threads. Coat threads with adhesive. Install adjusting screw. Turn screw until free play between lever and caliper stop is.024-.028" (.60 -.70 mm). Have assistant release brake pedal, then apply brake pedal firmly 3 times. Recheck free play. Adjust again if necessary. Install lever return spring. Reconnect parking brake cable.
Scheme 2
- Clean and lubricate threads on adjusting rod of parking brake cable equalizer. Adjust rear brakes. See REAR BRAKE SHOES under ADJUSTMENTS. Press parking brake lever 6 ratchet clicks.
- Raise and support vehicle. Tighten adjuster nut at equalizer until right rear wheel can just be turned rearward with 2 hands but cannot be turned forward. Release parking brake. Ensure rear wheels turn freely.
Adjust rear brakes. See REAR BRAKE SHOES under ADJUSTMENTS. No other information is available from manufacturer.
POWER BRAKE BOOSTER PISTON ROD
Note. Use the following procedure to measure how far booster piston rod protrudes from booster when vacuum is applied to booster. Piston rod is not adjustable. If piston rod protrusion is out of limits, replace rod with an adjustable service rod.
- Booster does not have to be installed to perform procedure. Apply 25 in. Hg vacuum or the MAXIMUM available engine vacuum to booster. Position Piston Rod Gauge (J-37839) over piston rod. (Scheme 3) One side of gauge measures minimum rod length. Other side measures maximum rod length.
- If piston rod length does not fall between maximum and minimum dimensions, disassemble booster. See OVERHAUL. Replace piston rod with an adjustable service piston rod (with self-locking screw) to make adjustments.
Scheme 3
BRAKELIGHT SWITCH
Hold brake pedal in applied position. Press switch fully forward until switch body is seated. Pull brake pedal fully rearward against pedal stop with 50 lbs. (22.5 kg) of pressure. DO NOT exceed specified pressure or power brake booster may be damaged. Switch is now adjusted. Ensure brakelights do not stay on with brake pedal at rest (unapplied).
REMOVAL & INSTALLATION
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery. |
Removal
Remove caliper. See FRONT BRAKE CALIPER. Remove outer pad from caliper using a screwdriver to disengage pad retaining buttons. (Scheme 5)and (Scheme 6). Remove inner pad.
Installation
- Clean outside surface of caliper piston boot with denatured alcohol. (Scheme 5)and (Scheme 6). Slowly compress piston into bore with a "C" clamp, being careful not to cock piston to one side or damage piston boot. Using small piece of plastic or wood, lift inner edge of boot next to piston and press out any trapped air. Reposition boot so it lays flat with convolutions in proper position.
- Install inner pad, snapping retainer into place in piston. Ensure pad lays flat against piston. Ensure boot is not touching pad. Install outer pad with wear sensor facing downward. Ensure pad lays flat against caliper. To install remaining components, reverse removal procedure.
- Remove and discard 2/3 of brake fluid from master cylinder reservoir to prevent overflow when servicing. Raise and support vehicle. Mark wheel in relation to hub. Remove wheel. On Camaro and Firebird, install and finger-tighten 2 lug nuts with flat side toward rotor to hold rotor when caliper is removed.
- On all vehicles, if not completely removing caliper (such as for overhaul), go to next step. If completely removing caliper, remove bolt securing brake hose to caliper. Disconnect brake hose from caliper. Plug opening in brake hose and caliper to prevent fluid loss and contamination.
- Position "C" clamp with stationary end of clamp on caliper housing and threaded end on outboard pad. Tighten "C" clamp until piston is pushed into bore far enough to slide caliper off of rotor. Remove "C" clamp.
- Remove caliper bolts and bushings. (Scheme 5)or (Scheme 6). Remove caliper. If brake hose is still connected to caliper, hang caliper by wire so brake hose will not be damaged. Remove pads from caliper.
- Liberally coat inner diameter of bushings with silicone grease. (Scheme 5)or (Scheme 6). Install caliper. Install caliper bolts and bushings. If bolts slide through bushings using hand pressure, go to step 3).
- If bolts do not slide through bushings using hand pressure, remove bolts and bushings. Inspect caliper bores for corrosion. If corrosion is found on Fleetwood, Caprice and Roadmaster, replace bushings. If corrosion is found on Camaro and Firebird, remove corrosion using 1" (25.4 mm) diameter wheel cylinder honing brush. On all vehicles, clean bores with clean denatured alcohol. Install and lubricate bushings. Install caliper bolts.
- Tighten caliper bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article. If brake hose was not disconnected, go to next step. If brake hose was disconnected, connect brake hose to caliper. Tighten fitting bolt to specification. Bleed brake hydraulic system, and go to next step. See BLEEDING BRAKE SYSTEM.
- Apply brakes several times to seat pads. Install wheel, aligning marks made during removal. Tighten wheel lug nuts to specification. Fill brake fluid reservoir. Road-test vehicle.
Removal (Caprice, Fleetwood and Roadmaster)
Raise and support vehicle. Remove wheel. Remove ABS wheel speed sensor from spindle. Remove and support caliper. See FRONT BRAKE CALIPER. Remove grease cap, cotter pin, nut and washer. Remove rotor.
Installation (Caprice, Fleetwood and Roadmaster)
- To install, reverse removal procedure. To adjust wheel bearings, tighten spindle nut to 12 ft. lbs. (16 N.m) while spinning rotor forward by hand. Back off nut until just loose, then hand-tighten.
- Tighten nut until either hole in spindle aligns with a slot in nut. DO NOT move nut more than 1/2 flat. Install NEW cotter pin. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article.
Removal & Installation (Camaro and Firebird)
Raise and support vehicle. Remove and support caliper. See FRONT BRAKE CALIPER. Remove rotor. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article.
Removal (Camaro and Firebird)
- Remove 2/3 of brake fluid from master cylinder reservoir. Raise and support vehicle. Mark wheel in relation to wheel studs. Remove wheel. Install 2 wheel lug nuts finger-tight to retain rotor. Position "C" clamp with one end on brake hose fitting bolt and other end on outer pad.
- Tighten "C" clamp until piston is bottomed in caliper. Remove and discard upper guide pin securing caliper to spindle. (Scheme 7) Rotate caliper downward on lower guide pin. Remove pads and shim. Discard shim.
Installation (Camaro and Firebird)
- Clean residue from pad guide surfaces on caliper mounting bracket and caliper housing. Replace guide pins or boots if corroded or damaged. Install NEW shim and pads. Install inner pad with wear sensor on leading edge of inner pad (assuming forward wheel rotation).
- Apply hand pressure to parking brake lever. (Scheme 7) Check free play between lever and housing. If free play is.024-.028" (.60 -.70 mm), go to next step. If free play is not.024-.028" (.60 -.70 mm), remove adjusting screw. Clean screw threads. Coat screw threads with adhesive. Install adjusting screw. Turn adjusting screw until free play is as specified.
- Rotate caliper housing into position. Ensure springs on outer pad do not stick through inspection hole in caliper housing. Install NEW upper guide pin. Tighten to specification. See TORQUE SPECIFICATIONS table at the end of this article. Start engine. Pump brake pedal slowly and firmly to seat pads.
- Check parking brake levers to see if they are against stops on caliper. If levers are not against stops, repair or adjust parking brake linkage as necessary. Install wheels. Fill master cylinder reservoir. Drive vehicle.
- Raise and support vehicle. Disconnect front parking brake cable from rear cables at equalizer. Mark wheel in relation to hub. Remove wheel. Install and finger-tighten 2 lug nuts with flat side toward rotor to hold rotor when caliper is removed.
- If not completely removing caliper (such as for overhaul), go to next step. If completely removing caliper, remove bolt securing brake hose to caliper. Disconnect brake hose from caliper. Plug opening in brake hose and caliper to prevent fluid loss and contamination.
- Remove parking brake lever return spring. (Scheme 7) Disconnect parking brake cable from parking brake lever and bracket. Remove vibration dampener from parking brake cable bracket, if necessary. Remove and discard upper and lower caliper guide pins. Remove caliper (suspend with wire if not completely removing).
- Replace guide pins or boots if corroded or damaged. (Scheme 7) Install caliper housing over rotor. Install NEW upper and lower guide pins. Tighten to specification. See TORQUE SPECIFICATIONS table at the end of this article.
- If brake hose was not disconnected, go to next step. If brake hose was disconnected, connect brake hose to caliper. Tighten fitting bolt to specification. Bleed brake hydraulic system and go to next step. See BLEEDING BRAKE SYSTEM.
- Install vibration dampener (if removed). Connect parking brake cables to levers and equalizer (if disconnected). Apply brakes several times to seat pads. Check parking brake levers to see if they are against stops on caliper. If levers are not against stops, repair or adjust parking brake linkage as necessary.
- Install wheel. Tighten wheel lug nuts to specification. Fill brake fluid reservoir. Road-test vehicle.
Remove caliper and wire aside. See REAR BRAKE CALIPER. Mark rotor in relation to hub for installation reference. Remove rotor. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article.
Note. Observe locations of springs, adjuster assembly and brake shoes for reassembly reference.
- Remove wheels and drums. Remove brake components in order listed in illustration. (Scheme 8)and (Scheme 10). Clean brake components and backing plate with denatured alcohol. Lubricate threads of adjuster assembly and shoes lands on backing plate with White grease.
- To install, reverse removal procedure. Adjust rear brake shoes. See REAR BRAKE SHOES under ADJUSTMENTS. Install wheels. Tighten wheel lug nuts to specification. See TORQUE SPECIFICATIONS table at the end of this article. Adjust parking brake. See PARKING BRAKE (DRUM) under ADJUSTMENTS. Road test vehicle.
Remove brake fluid from master cylinder reservoir. Disconnect brakelines from master cylinder. Plug openings. Disconnect hose from reservoir (if equipped). Plug opening. Remove nuts securing master cylinder to power brake booster. On Fleetwood, Caprice and Roadmaster, move combination valve out of way. On all vehicles, remove master cylinder.
Bench bleed master cylinder. To complete installation, reverse removal procedure. Tighten master cylinder nuts and brakeline fittings to specification. See TORQUE SPECIFICATIONS table at the end of this article. Bleed brake system. See BLEEDING BRAKE SYSTEM.
POWER BRAKE BOOSTER
Note. Power brake booster can be removed without completely removing master cylinder, but if both components are to be removed, remove master cylinder first.
- Disconnect vacuum hose from check valve on booster. Remove nuts securing master cylinder to booster. Move combination valve bracket and master cylinder forward to clear studs on booster. DO NOT move more than necessary or brakelines may be damaged.
- Remove left sound insulator from below instrument panel. Working in passenger compartment, remove 4 nuts securing booster to firewall. Separate brake pedal from booster push rod. Remove Daytime Running Lights (DRL) diode assembly (if equipped). Remove booster and gasket.
- Disconnect air injection pipe from exhaust manifold and move pipe out of way (if necessary). Disconnect vacuum hose from check valve on booster. Remove nuts securing master cylinder to booster. Move master cylinder forward to clear studs on booster. DO NOT move more than necessary or brakelines may be damaged.
- Remove left sound insulator from below instrument panel. Working in passenger compartment, remove 4 nuts securing booster to brake pedal assembly. On manual transmission, loosen nuts securing brake/clutch pedal assembly. Pull back on brake/clutch pedal assembly for access to booster nuts.
- On all vehicles, remove and discard booster nuts (nuts are needed only for factory assembly). Remove retainer and washer securing push rod to brake pedal. Tilt entire booster slightly to work push rod off of brake pedal pin. DO NOT put undue side pressure on push rod. Remove booster.
Note. On Caprice, Fleetwood and Roadmaster ensure accelerator and cruise control cables do not get caught between booster and firewall during installation. If cables become damaged or pinched, they MUST be replaced to prevent accelerator pedal from binding.
Installation (All Models)
To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS table at the end of this article. Adjust brakelight switch. See BRAKELIGHT SWITCH under ADJUSTMENTS.
Remove rear brake shoes. See REAR BRAKE SHOES. Disconnect inlet tube nut and line. Plug opening in line to prevent fluid loss and contamination. Remove wheel cylinder bolts and wheel cylinder. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Disconnect electrical connector from brake pressure differential switch on combination valve. Disconnect brakelines from combination valve. Plug brake lines to prevent loss of fluid and contamination. Remove 2 nuts securing combination valve to booster studs. Remove combination valve.
To install, reverse removal procedure. Tighten nuts and brakeline fittings to specification. See TORQUE SPECIFICATIONS table at the end of this article. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Scheme 4
- Using Tech 1 scan tester, perform gear tension release procedure. See Tech 1 scan tester instructions for more information. Remove air cleaner duct assembly. Disconnect electrical connectors from ABS modulator solenoids, brake pressure differential switch on combination valve and ABS modulator motor pack. (Scheme 4)
- Place shop cloth on top of motor pack to catch dripping brake fluid. Disconnect brakelines from combination valve and ABS modulator. Plug openings. DO NOT allow brake fluid to enter bottom of motor pack or electrical connectors. Remove bolt securing front of ABS modulator to frame rail.
- Remove ABS modulator. Remove 2 Torx head screws securing gear cover to bottom of ABS modulator. Remove gear cover. Remove 4 Torx head screws securing motor pack to ABS modulator. Remove motor pack.
- Remove 2 banjo bolts securing ABS modulator to combination valve. Separate ABS modulator from combination valve. Remove 2 transfer tubes installed between ABS modulator and combination valve. Remove banjo bolt "O" rings from ABS modulator and combination valve.
- Lubricate NEW "O" rings with clean brake fluid. Set "O" rings into position. Install NEW transfer tubes into ports on ABS modulator, pressing tubes by hand until bottomed in bore. (Scheme 4)
- Holding combination valve, rock it into position on ABS modulator, inserting transfer tubes into combination valve ports. Lubricate NEW banjo bolt "O" rings. Install banjo bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at the end of this article.
- With ABS modulator upside down (gears facing up), rotate each gear counterclockwise until stopped. This positions pistons close to top of modulator bore, simplifying brake bleeding procedure. To install remaining components, reverse removal procedure. Bleed brake system. See appropriate ANTI-LOCK BRAKE SYSTEM article.
- Raise and support vehicle. Remove wheel. On drum brakes, remove drum and go to next step. On disc brakes, remove caliper and wire aside. See REAR CALIPER. Remove rotor. Go to next step.
- Remove rear axle housing cover. Install ABS Sensor Ring Protector (J-39446) onto ABS sensor ring (Camaro and Firebird). Remove lock bolt securing pinion gear shaft in differential case. Remove pinion gear shaft from differential case.
- Push outer (flanged) end of axle shaft inward. Remove axle shaft lock from inner end of axle shaft in differential case. Remove axle shaft. Carefully pry axle shaft oil seal from housing. DO NOT damage housing. Position slide hammer into bore so tangs engage bearing outer race. Remove axle shaft bearing.
Lubricate NEW axle shaft bearing with gear lubricant. Using bearing installer, install axle shaft bearing so bearing installer bottoms against shoulder in housing. Lubricate NEW oil seal lip with gear lubricant. Using oil seal installer, install oil seal into housing bore until even with axle tube. To install remaining components, reverse removal procedure. Fill rear axle with gear lubricant.
OVERHAUL
Note. For overhaul procedures, use exploded views. (Scheme 5)- (Scheme 12) Exploded view of power brake booster is not available for Camaro and Firebird.
Scheme 5
Scheme 6
Scheme 7
Scheme 8
Scheme 9
Scheme 10
Scheme 11
Scheme 12
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) | ||
|---|---|---|---|
| ABS Modulator-To-Combination Valve | |||
| Banjo Bolt (Camaro and Firebird) | 12 (16) | ||
| AIR Tube-To-Exhaust Manifold | |||
| Fitting (Camaro and Firebird) | 25 (34) | ||
| Brakeline/Brake Hose Fitting | |||
| At ABS Modulator (Camaro and Firebird) | 24 (33) | ||
| At Caliper | 32 (43) | ||
| At Combination Valve | 11 (15) | ||
| At Master Cylinder | 24 (33) | ||
| At Wheel Cylinder | |||
| Caprice, Fleetwood and Roadmaster | 18 (24) | ||
| Camaro and Firebird | 13 (18) | ||
| Caliper Bolt/Pin | |||
| Front | 38 (52) | ||
| Rear | 27 (37) | ||
| Combination Valve-To-Booster | |||
| Nut (Caprice, Fleetwood and Roadmaster) | 20 (27) | ||
| Master Cylinder-To-Booster Nut | |||
| Caprice, Fleetwood and Roadmaster | 20 (27) | ||
| Camaro and Firebird | 32 (43) | ||
| Power Brake Booster-To-Firewall Nut | 20 (27) | ||
| Wheel Cylinder Bolt (Caprice, Fleetwood & Roadmaster) | 13 (18) | ||
| Wheel Lug Nut | 100 (136) | ||
| INCH lbs. (N.m) | |||
| Bleeder Screw | |||
| At ABS Modulator (Fleetwood) | 80 (9) | ||
| At Caliper | 115 (13) | ||
| At Wheel Cylinder | 62 (7) | ||
| Wheel Cylinder Bolt (Camaro and Firebird) | 115 (13) | ||
TORQUE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
| Application | In. (mm) | ||
|---|---|---|---|
| Disc Diameter | |||
| Caprice, Fleetwood and Roadmaster | 12.00 (305) | ||
| Camaro and Firebird | |||
| Front | 10.94 (278) | ||
| Rear | 11.54 (293) | ||
| Lateral Runout | |||
| Roadmaster | .003 (.08) | ||
| Fleetwood | .004 (.10) | ||
| Camaro and Firebird | |||
| Front | .005 (.13) | ||
| Rear | (1) | ||
| Parallelism | .0005 (.013) | ||
| Original Thickness | |||
| Caprice, Fleetwood & Roadmaster | 1.043 (26.50) | ||
| Camaro and Firebird | |||
| Front | 1.260 (32.00) | ||
| Rear | .787 (20.00) | ||
| Minimum Refinish Thickness | |||
| Caprice, Fleetwood & Roadmaster | .980 (24.89) | ||
| Camaro and Firebird | |||
| Front | 1.250 (31.74) | ||
| Rear | .733 (18.63) | ||
| Discard Thickness (2) | |||
| Caprice, Fleetwood & Roadmaster | .965 (24.51) | ||
| Camaro and Firebird | |||
| Front | 1.209 (30.70) | ||
| Rear | .724 (18.40) | ||
| (1) On-vehicle runout must not exceed .006" (.15 mm). Rear axle shaft flange runout must not exceed .002" (.05 mm). (2) Use specification stamped on rotor. | |||
| (1) | On-vehicle runout must not exceed .006" (.15 mm). Rear axle shaft flange runout must not exceed .002" (.05 mm). |
| (2) | Use specification stamped on rotor. |
DISC BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
| Application | In. (mm) | |
|---|---|---|
| Drum Diameter | ||
| Caprice, Fleetwood & Roadmaster | 11.000 (279.40) | |
| Camaro and Firebird | 9.500 (241.30) | |
| Maximum Refinish Diameter | ||
| Caprice, Fleetwood & Roadmaster | 11.060 (280.92) | |
| Camaro and Firebird | 9.560 (242.82) | |
| Discard Diameter (1) | ||
| Caprice, Fleetwood & Roadmaster | 11.090 (281.68) | |
| Camaro and Firebird | 9.590 (243.59) | |
| Drum Runout | .006 (.15) | |
| Wheel Cylinder Diameter | ||
| Roadmaster | 7/8 (22.2) Or 1.0 (25.4) | |
| Fleetwood | 1.0 (25.4) | |
| Camaro and Firebird | .81 (20.6) | |
| (1) Use specification stamped on drum. | ||
| (1) | Use specification stamped on drum. |
DRUM BRAKE SPECIFICATIONS