REMOVAL & INSTALLATION
| WARNING | Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. |
| WARNING | Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. |
| CAUTION | Do not allow the brake master cylinder degas bottle to run dry during the bleeding operation. Keep the brake master cylinder degas bottle filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. |
| CAUTION | Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. |
- Disconnect the brake switch connector. (Scheme 1)
- Remove in the order indicated. Spring pin. Clevis pin. Brake pedal. Brake switch. Pedal pad.
- Install in the reverse order of removal. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
Scheme 1
- Raise and support front of vehicle. Remove front wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 2)
- Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164090-S27679391592004072100000). Install in the reverse order of removal. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
- After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
Note. Mark the wheel hub bolt and disc plate before removal for reference during installation. (Scheme 3)
Note. When installing disc pads use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install brake pads. (Scheme 4) When installing disc pads use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install brake pads. See
Scheme 2
Scheme 3
Scheme 4
Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt. Remove caliper from vehicle. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .
- Raise and support front of vehicle. Remove front wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 5) Remove lower guide pin. Pivot caliper upward, and wire aside.
- Replace pad if lining thickness is less than specified. See «DISC BRAKE SPECIFICATIONS»(ref-164090-S27679391592004072100000).
- To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install brake pads. (Scheme 4) Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
Scheme 5
- Remove the air cleaner.
- Remove the air filter.
- Disassemble in the order indicated in the illustration. (Scheme 6)
- Install in the reverse order of removal. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164090-S30745845232004072100000).
Scheme 6
Master Cylinder Installation Note (For Vehicles With Rear Disc Brakes)
- Loosen the adjusting nut of the Adjustment Gauge (49-B043-001).
- Place the adjustment gauge on the power brake unit and tighten the nut and washer. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
- Using a vacuum pump, apply 19.7 in. Hg (66.7 kPa) of vacuum.
- Turn the adjusting nut of the adjustment gauge rod counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. (Scheme 7) Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and adjustment gauge rod body. CAUTION: When pushing the adjustment gauge rod into the master cylinder piston, only use enough pressure to push the rod to the bottom of the piston. If too much pressure is applied, a false reading will occur.
- Remove the adjustment gauge from the power brake unit without disturbing the adjusting nut. Set the adjustment gauge onto the master cylinder as shown in the illustration. (Scheme 7)
- Push lightly on the end of the adjustment gauge rod to be sure it has contacted the bottom of, the master cylinder piston, but do not push so hard that the piston moves. (Scheme 8) Note any clearance between the adjustment gauge body and the adjusting nut clearance at "B" or between the body and the master cylinder clearance at "C". See «ADJUSTING PUSH ROD»(ref-164090-S42751193232004061000000) table. To adjust the push rod, see «MASTER CYLINDER PUSH ROD»(ref-164090-S22181912402004072300000) under ADJUSTMENTS.
| Measurement | Push Rod |
|---|---|
| Clearance At "B" | Too Short |
| Clearance At "C" | Too Long |
| No Clearance At "B" Or "C" | Too Long |
ADJUSTING PUSH ROD
Scheme 7
Scheme 8
Master Cylinder Installation Note (For Vehicles With Rear Drum Brakes)
- Place the Adjustment Gauge (49-F043-001) atop the master cylinder. (Scheme 9) Turn the adjusting bolt until it touches the bottom of the push rod hole in the piston.
- Apply 19.7 in. Hg (66.7 kPa) vacuum to the power brake unit using a vacuum pump.
- Invert the adjustment gauge and place it on the power brake unit. (Scheme 10)
- Measure the clearance between the end of the Rod Holder (49-E043-003A) and the push rod of the power brake unit. see scheme 6 If it is not 0" (0 mm), loosen the push rod lock nut and turn the push rod to adjust it by using the Socket (49-B043-004).
Scheme 9
Scheme 10
- Raise and support vehicle. Remove rear wheel assemblies. Remove in the order indicated in the illustration. (Scheme 11) CAUTION: Be careful not to allow components to come flying off the brake assembly. NOTE: When removing the brake caliper assembly suspend it out of the way so that it dose not interfere. NOTE: If any disc plate is difficult to remove, insert a flat head screwdriver in to the service hole and turn the adjuster in the direction of the arrows in the illustration, to compress the parking brake shoe. (Scheme 12) NOTE: When removing the parking brake shoe, pull the parking shoe upward and disengage it from the shoe stopper. Press the adjuster bolt and tappet by hand, and slowly remove the parking brake shoe. (Scheme 13)
- To install, reverse removal procedure. Adjust parking brake. See «PARKING/EMERGENCY BRAKE»(ref-164090-S38016167272004072100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). If necessary bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-164090-S30745845232004072100000). NOTE: When installing the adjuster bolt, nut, and tappet, install them so that the adjuster nut is facing toward the front of the vehicle. (Scheme 14) Completely tighten the adjuster bolt and nut. NOTE: After installation, verify that there is no gap between the adjuster bolt or tappet and the cylinder. (Scheme 15) If there is a gap due to improper installation of the operation lever, reinstall while pressing the operation lever completely inward. Move the operation lever by hand and verify that it operates properly. If proper operation cannot be verified, reinstall. NOTE: When installing the brake shoe, measure the parking brake lining thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164090-S27679391592004072100000). If it is less than the minimum thickness, install a new parking brake shoe. Install the parking brake shoe so that the marking is facing outward.
- After installing the opening of the parking brake shoe to the adjuster bolt and tappet, push the brake shoe downward and attach it to the shoe stopper. (Scheme 16) NOTE: When installing the disc plate, measure the inner diameter of the disc plate. See «DISC BRAKE SPECIFICATIONS»(ref-164090-S27679391592004072100000). If it is exceeds than the maximum thickness, install a new disc plate.
- After installation of the disc plate, to adjust the shoe clearance insert a flathead screwdriver into the service hole and turn the adjuster in the direction of the arrows in the illustration, to expand the parking brake shoe, continue until the disc plate cannot rotate. (Scheme 17) Then turn the adjuster back 13-17 notches, at 15 notches back, the shoe clearance will be 0.006" (0.15 mm). Rotate the disc plate and make sure that it dose not drag.
Scheme 11
Scheme 12
Scheme 13
Scheme 14
Scheme 15
Scheme 16
Scheme 17
Removal
Raise and support vehicle. Remove rear wheel assemblies. Remove in the order indicated in the illustration. (Scheme 18)
Scheme 18
Installation
To install, reverse removal procedure. Adjust parking brake. See PARKING/EMERGENCY BRAKE under ADJUSTMENTS. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . If necessary bleed brake system. See BLEEDING BRAKE SYSTEM .
- Remove the master cylinder. See «MASTER CYLINDER»(ref-164090-S03782956622004072100000).
- Remove the battery.
- Remove in the order indicated in the illustration. (Scheme 19)
- Install in the reverse order of removal. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164090-S30745845232004072100000).
Scheme 19
- Raise and support vehicle. Remove rear wheel assemblies. Remove in the order indicated in the illustration. (Scheme 20)
- Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164090-S27679391592004072100000).
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
- After installation, depress the brake pedal a few times. Then verify that the brakes do not drag. Inspect the pedal-to-floor clearance. Inspect the parking lever stroke. NOTE: For brake pads, see «REAR DISC BRAKE PADS»(ref-164090-S12697477632004072600000).
Scheme 20
- Raise and support vehicle. Remove rear wheel assemblies.
- Remove in the order indicated in the illustration. (Scheme 21) NOTE: On brake drum removal, mark the wheel hub bolt and brake drum before removal for reference during installation. Front rotor is shown. (Scheme 3)
- Install in the reverse order of removal.
- After installation, perform the following. Depress the brake pedal a few times. Then verify that the brakes do not drag. Inspect the pedal-to-floor clearance. See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-164090-S33976430182004072100000) table. Inspect the parking brake lever stroke. See «PARKING/EMERGENCY BRAKE»(ref-164090-S38016167272004072100000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). Bleed air from system if necessary. See «BLEEDING BRAKE SYSTEM»(ref-164090-S30745845232004072100000).
Note. Ensure that the drums/shoes are adjusted properly. See REAR BRAKE DRUMS/SHOES under ADJUSTMENTS.
Note. Rear brake lining thickness inspection. Remove the brake drum. Inspect the remaining thickness of the lining. Replace both left and right brake shoes if either is at or less than the minimum thickness. See DRUM BRAKE SPECIFICATIONS .
Note. Rear brake drum inspection. Measure the inner diameter of the drum. Inspect for scratches and uneven or abnormal wear inside the drum. Repair or replace the drum as necessary. When repairing or replacing the drum, inspect the contact with the shoes. Machine or replace as necessary if not as specified. See DRUM BRAKE SPECIFICATIONS .
Scheme 21
- Raise and support vehicle. Remove rear wheel assemblies. Remove in the order indicated in the illustration. (Scheme 22)
- To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install brake pads. (Scheme 23) Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). If necessary bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-164090-S30745845232004072100000).
