INSTALLATION - DISC BRAKE CALIPER (REAR)
CAUTION: If the brake shoes are being replaced, the rear caliper piston must be seated (bottomed) to compensate for new brake lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore with Special Tool 8807 as described below. Any other seating method will damage the self-adjuster mechanism.
If necessary, seat (bottom) the caliper piston in the bore as follows:
Assemble a 3/8 in. drive ratchet handle and an extension.
Insert the extension through Special Tool 8807–1.
Place Special Tool 8807–2 on the end of the extension.
Insert lugs on Special Tool 8807–2 into notches in face of caliper piston (Seating Piston With Special Tool).
Thread the screw drive on 8807–1 down until it contacts the top of 8807–2 which is against the caliper piston (Seating Piston With Special Tool). Do not over tighten the screw drive. Damage to the piston can occur.
Turn 8807–2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807–1 with 8807–2 to start the process of piston retraction.
Once seated, align the notches in the piston with the boss on the caliper as shown (Piston Notches Lined Up). This is necessary to allow proper mating of the piston to the inboard brake shoe once installed (a lug on the rear of the shoe fits into the notch).
Remove the tools.
CAUTION: When installing the caliper, make sure the flats on the guide pin heads are lined up with the flat edges of caliper mounting flanges or damage to the pins will occur and the guide pin bolts may not install properly.
Install brake caliper over the brake shoes aligning the lug on the inboard shoe with the properly aligned notch in the piston (Piston Notches Lined Up). Use care not to damage guide pin boots as the caliper is placed over the guide pins.
Install the two guide pin bolts (Rear Brake Caliper Mounting). Tighten the bolts to 33 N·m (24 ft. lbs.) torque.
Install the parking brake cable through the caliper bracket (Parking Brake Cable Attachment To Caliper).
Rotate the parking brake operating lever upward and attach the end of the parking brake cable (Parking Brake Cable Attachment To Caliper).
Position 2 new copper seal washers on each side of the brake hose fitting and install the banjo bolt through it, then install the banjo bolt into the caliper fluid port (Rear Brake Caliper Mounting). Tighten the banjo bolt to 48 N·m (35 ft. lbs.) torque.
Remove the brake pedal prop and bleed the rear brake caliper. (Refer to 5 - BRAKES - STANDARD PROCEDURE).
Install the wheel and tire assembly (Refer to 22 - TIRES/WHEELS - INSTALLATION). Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 122 N·m (90 ft. lbs.).
Apply the brakes several times to seat the brake shoes and equalize parking brake adjustment.
NOTE: Before vehicle is moved after any brake service work, be sure to obtain a firm brake pedal.
Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. New brake shoes need to be properly burnished. To do so, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - STANDARD PROCEDURE).
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