Disc & Drum: Removal & Installation Eagle Vision I

REMOVAL & INSTALLATION

Removal

1. Raise and support vehicle. Remove wheel. Remove caliper guide pin bolts. Remove caliper assembly from steering knuckle and brake disc. First rotate top of caliper away from steering knuckle, then lift caliper assembly off bottom machined abutment on steering knuckle.
2. Firmly support and secure caliper to keep weight off flexible brake hose. Remove outboard brake shoe by prying shoe retaining clip over raised area on caliper. Then slide shoe down and off caliper. Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston.

Installation

Clean and lubricate caliper-to-caliper adapter sliding surfaces. Completely retract piston into piston bore. Install inboard pad assembly into caliper piston. Slide outboard pad onto caliper assembly. To complete installation, reverse removal procedure. When installing caliper guide pins, tighten to 30 ft. lbs. (41 N.m). Ensure guide pin bolts are not cross-threaded. Pump brake pedal several times until pedal is firm.

Removal (5 Passenger Models)

1. Disconnect negative battery cable. Remove adjuster attaching bolts and nuts from floor pan. Move seat position adjuster for access. Disconnect wiring harness at carpet. Remove seat assembly.
2. Remove shift knob from floor shifter. Shift knob is removed be removing 3/32 INCH Allen head set screw located on drivers side of shift knob and pulling strait up on shift knob.
3. Remove upper center console cover from vehicle if equipped.
4. Remove drivers side door opening sill molding. Remove drivers side cowl kick molding to expose park brake pedal mechanism.
5. Remove rear console mounting bracket from park brake cable reaction bracket. Remove rear passenger compartment heat duct from vehicle, for access to park brake cables.
6. Fold back carpeting to expose front park brake cable and routing clips.

Removal (6 Passenger Models)

1. Disconnect negative battery cable. Remove adjuster attaching bolts and nuts from floor pan. Move seat position adjuster for access. Disconnect wiring harness at carpet. Remove seat assembly.
2. Remove rear seat lower cushion from vehicle.
3. Remove drivers side door opening sill molding. Remove drivers side cowl kick molding to expose park brake pedal mechanism.
4. Fold back carpeting to expose front park brake cable, reaction bracket cover and equalizer.

Scheme 3

Removal (All Models)

1. Reload park brake assembly self adjuster. See «Reloading Self Adjuster»(ref-27173-S01346190382001011500000).
2. Remove front park brake cable from park brake cable equalizer. (Scheme 4)
3. Remove the front park brake cable to reaction bracket retaining clip, by prying it off cable using a screwdriver. (Scheme 5)
4. Remove front park brake cable from reaction bracket. Remove screw, attaching park brake cable routing clip to left front floor pan. Remove front park brake cable from the 2 routing clips attached to the floor pan crossmember.
5. Remove the bolt attaching park brake pedal assembly to left front door frame. Loosen but do not remove the 2 bolts attaching park brake pedal assembly to cowl panel. Unplug the brake warning light connector from switch on park brake pedal assembly. Remove park brake pedal mechanism and front park brake cable as an assembly.
6. Mount park brake pedal assembly in a vise. Remove front park brake cable to park brake assembly retaining clip.
7. After park brake pedal assembly is removed from vehicle body. Rotate park brake cable to align cable with notch in cable attaching hole on park brake pedal mechanism. Lift lead slug of park brake cable, out of retaining hole in park brake mechanism, then remove park brake cable from park brake mechanism.

Scheme 4

Scheme 5

Installation (All Models)

1. Install park brake cable assembly, through cable mounting in park brake pedal mechanism.
2. Align park brake cable slug with attaching hole on park brake assembly. Install park brake cable into cable attaching hole in park brake assembly, and rotate cable into place. Be sure cable is properly seated in the cam surface track of foot lever assembly. (Scheme 6)
3. Install park brake cable to park brake pedal mechanism retaining clip. Be sure retaining clip is fully installed on park brake cable.
4. Install park brake pedal mechanism onto the 2 loosened mounting bolt on cowl panel. Install the park brake pedal assembly retaining bolt into door frame. Torque all 3 park brake assembly mounting bolts to 19 ft. lbs (27 N.m).
5. Connect the brake warning light wire from vehicles wiring harness, onto switch located on park brake pedal mechanism.
6. Route front park brake cable along floor of vehicle. Install end of front park brake cable into mounting hole in reaction bracket. Install front park brake cable to reaction bracket retaining clip. Tap retaining clip with hammer until fully installed on cable. Install front park brake cable into equalizer.
7. Install the park brake cable routing clip to floor pan attaching screw. Torque the routing clip to floor pan attaching screw to 35 INCH lbs. (4 N.m). Install front park brake cable into routing clips on floor pan crossmember.
8. Ensure that park brake cable is properly routed in cam surface track of park brake pedal assembly. Using a pair of pliers, firmly grasp lock pin previously installed in park brake mechanism. Remove lock pin from park brake pedal mechanism, using a firm and rapid pull. When locking pin is removed from park brake pedal mechanism, the park brake mechanism and park brake cables will automatically adjust. See «PARKING/EMERGENCY BRAKE»(ref-27173-S37563022782001011500000) under ADJUSTMENTS.

Scheme 6

Installation (5 Passenger Models)

1. Fold carpeting back into position on left floor pan of vehicle. Install throttle pedal and bracket back on dash panel studs and install attaching nuts.
2. Install rear passenger compartment heat duct back into vehicle. Install rear console assembly mounting bracket on the park brake cable reaction bracket. Torque rear console assembly mounting bracket to reaction bracket mounting bolts to 88 INCH lbs. (10 N.m).
3. Install drivers side cowl kick molding. Install drivers side door opening sill molding.
4. Install upper center console cover assembly back in vehicle.
5. Install shift knob on floor shifter (if equipped). Shift knob is installed by pushing shift knob down shift shaft until fully bottomed. Then install and tighten 3/32 INCH Allen head set screw located on drivers side of shift knob.
6. Disconnect negative battery cable. Remove adjuster attaching bolts and nuts from floor pan. Move seat position adjuster for access. Disconnect wiring harness at carpet. Remove seat assembly.
7. When repairs are complete, adjust rear brakes before adjusting parking brake. See «Parking Brake Adjusting Procedure»(ref-27173-S26261242732004040100000) . On drum-in-hat type of rear disc brake adjust shoe diameter to 6.75 INCH (171.5 mm).

Installation (6 Passenger Models)

1. Install equalizer cover back on reaction bracket. Torque equalizer cover to reaction bracket mounting bolts to 88 INCH lbs. (10 N.m). Fold carpeting back into position on left floor pan or vehicle. Install throttle pedal and bracket back on dash panel studs and install attaching nuts.
2. Install drivers side cowl area kick molding back in vehicle. Install drivers side door opening sill molding.
3. Install rear seat lower cushion back in vehicle.
4. Install drivers side seat assembly back vehicle
5. When repairs are complete, adjust rear brakes before adjusting parking brake. See «Parking Brake Adjusting Procedure»(ref-27173-S26261242732004040100000) .

1. Raise and support vehicle. Remove wheel. Remove caliper guide pin bolts. Remove caliper assembly from steering knuckle and brake disc. First rotate top of caliper away from steering knuckle, then lift caliper assembly off bottom machined abutment on steering knuckle.
2. Firmly support and secure caliper to keep weight off flexible brake hose. Remove outboard brake shoe by prying shoe retaining clip over raised area on caliper. Slide shoe down and off caliper. Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston.

Clean and lubricate caliper-to-caliper adapter sliding surfaces. Completely retract piston into piston bore. Install inboard pad assembly into caliper piston. Slide outboard pad onto caliper assembly. To complete installation, reverse removal procedure. When installing caliper guide pins, tighten to 30 ft. lbs. (41 N.m). Ensure guide pin bolts are NOT cross-threaded. Pump brake pedal several times until pedal is firm.

Remove caliper assembly. See FRONT BRAKE CALIPER & PADS or REAR BRAKE CALIPER & PADS. Remove disc from hub. To install, reverse removal procedure.

1. Raise and support vehicle. Remove wheel. Remove cap from center of drum. Remove hub nut. Remove drum and hub assembly (if assembly is difficult to remove, unseat adjuster lever using small screwdriver, and loosen adjuster wheel).
2. Remove automatic adjuster spring from automatic adjuster lever. Rotate automatic adjuster screw assembly so each shoe assembly moves out far enough to be free of wheel cylinder boots.
3. Disconnect parking brake cable from parking brake lever. NOTE: Disconnect parking brake cable ONLY one side at a time. If both sides are disconnected, extreme effort will be required to connect parking brake cables to equalizer or parking brake lever.
4. Remove both lower brake shoe assembly-to-anchor plate springs. Remove both shoe assembly-to-backing plate hold down springs. Remove brake shoe assemblies, upper shoe-to-shoe return spring, automatic adjuster and adjuster lever from backing plate as an assembly.
5. After brake shoe assemblies are removed from backing plate, separate brake shoe assemblies from automatic adjuster mechanism. Remove brake shoe automatic adjuster lever from leading brake shoe assembly.

Clean brake shoe-to-backing plate contact surfaces, and lubricate with grease. Lubricate parking brake pivot pin with grease. For installation, reverse removal procedure. Tighten hub nut to 124 ft. lbs. (168 N.m). Adjust brake shoes. See REAR BRAKE SHOES under ADJUSTMENTS.

1. Raise and support vehicle. Remove rear wheel. Remove brake drum from hub. Remove shoes. See REAR BRAKE SHOES.
2. Disconnect brakeline from wheel cylinder. Remove wheel cylinder bolts and wheel cylinder. To install, reverse removal procedure. Bleed brakes. See BLEEDING PROCEDURES under BLEEDING BRAKE SYSTEM.

Place shop towel under master cylinder to absorb fluid. Disconnect primary and secondary brake tubes from master cylinder housing. Install plugs at brake tube outlets. Remove 2 nuts attaching master cylinder to power brake unit. Slide master cylinder straight out and away from brake booster unit.

Position master cylinder over studs on brake booster. Ensure alignment of push rod with master cylinder piston. Tighten mounting nuts to 21 ft. lbs. (28 N.m). Connect brake tubes to master cylinder and tighten fittings to 13 ft. lbs. (17 N.m).

1. Remove both wiper arm assemblies. Remove cowl panel cover to expose wiper module. Remove 5 screws attaching wiper module to dash panel and remove wiper module. Remove 2 nuts attaching master cylinder to brake booster. Carefully slide master cylinder off mounting studs with brakelines attached and allow assembly to rest against left shock tower.
2. Disconnect vacuum hose from brake booster check valve. DO NOT remove check valve from brake booster.
3. From under instrument panel, position a small screwdriver between center tang on booster input rod-to-brake pedal pin retaining clip. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull retainer clip off pin. Discard retainer clip.
4. Remove 4 nuts attaching booster to dash panel. (Nuts are accessible from under dash in area of steering column and pedal bracket.) Slide brake booster up and to right (mounting holes are slotted) on dash panel, then tilt outboard and up to remove.

For installation, reverse removal procedure. Tighten 4 booster mounting nuts and 2 master cylinder mounting nuts to 21 ft. lbs. (28 N.m). Lubricate pedal pin when installing. Use NEW retainer clip on booster input rod-to-brake pedal pin. Check stop light operation.

1. Disconnect proportioning valve pressure differential switch connector. Loosen all brakelines at valve. Loosen master cylinder-to-power brake unit nuts. Remove valve-to-bracket nut and bolt. Disconnect brakelines from valve, and remove valve.
2. Start brakelines on valve ( DO NOT tighten). Align valve with bracket, and tighten nut and bolt. Tighten master cylinder-to-power brake unit nuts. Tighten brakelines. Bleed brakes. Refer to «BLEEDING PROCEDURES»(ref-27173-S27337371382001011500000) under BLEEDING BRAKE SYSTEM.

Removal & Installation (Disc)

1. Raise and support vehicle. Remove wheel. Remove caliper. See REAR BRAKE CALIPER & PADS. Remove cap and hub nut.
2. Remove hub and bearing assembly. To install, reverse removal procedure. Apply bearing grease to axle shaft before installing hub. Tighten hub nut to 124 ft. lbs. (168 N.m).

Removal & Installation (Drum)

1. Raise and support vehicle. Remove wheel. Remove drum from hub. If drum is difficult to remove, unseat adjuster lever using small screwdriver, and loosen adjuster wheel.
2. Remove hub nut. Remove hub and bearing assembly. To install, reverse removal procedure. Apply bearing grease to axle shaft before installing hub. Tighten hub nut to 124 ft. lbs. (168 N.m).

1. Reload parking brake mechanism. See «Reloading Self Adjuster»(ref-27173-S01346190382001011500000) under ADJUSTMENTS.
2. Remove the brake warning light wire from the park brake mechanism switch. (Scheme 7)
3. Using a screw driver, pry the park brake cable retaining clip from the park brake cable.
4. Remove the 1 bolt holding park brake pedal assembly to door frame. Loosen but do not remove the 2 bolts attaching park brake pedal mechanism to inner body panel.
5. Remove park brake pedal mechanism and cable as an assembly from body of vehicle.
6. After park brake pedal assembly is removed from vehicle body. Rotate park brake cable to align cable with notch in cable attaching hole on park brake pedal mechanism. (Scheme 8) Lift lead slug of park brake cable, out of retaining hole in park brake mechanism, then remove park brake cable from park brake mechanism.

Scheme 7

Scheme 8

1. Install park brake cable assembly, through cable mounting in park brake pedal mechanism.
2. Align park brake cable slug with attaching hole on park brake assembly. Install park brake cable into cable attaching hole in park brake assembly, and rotate cable into place. Be sure cable is properly seated in the cam surface track in the foot lever assembly.
3. Install park brake cable to park brake pedal mechanism retaining clip. (Scheme 9) Be sure retaining clip is fully installed on park brake cable. Install park brake pedal return spring before installing park brake pedal assembly back in vehicle.
4. Install park brake pedal mechanism onto the 2 loosened mounting bolt on inner body panel. (Scheme 7) Torque all 3 park brake assembly mounting bolts to 19 ft. lbs. (27 N.m).
5. Connect the brake warning light wire from vehicles wiring harness, onto switch located on park brake pedal mechanism.
6. Ensure that park brake cable is properly routed in cam surface track of park brake pedal assembly. Using a pair of pliers, firmly grasp lock pin installed in park brake mechanism. Remove lock pin from park brake pedal mechanism, using a firm and rapid pull. When locking pin is removed from park brake pedal mechanism, the park brake mechanism and park brake cables will automatically adjust. See «PARKING/EMERGENCY BRAKE»(ref-27173-S37563022782001011500000).
7. When repairs are complete, adjust rear brakes before adjusting parking brake. On drum-in-hat type of rear disc brake adjust shoe diameter to 6.75 INCH (171.5 mm).

Scheme 9