POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
ROTORS
REMOVAL
REMOVAL - FRONT (SRW) . . . . . . . . . . . . . . 20
REMOVAL - REAR (SRW) . . . . . . . . . . . . . . . 20
REMOVAL - FRONT (DRW) . . . . . . . . . . . . . . 21
REMOVAL - REAR (DRW) . . . . . . . . . . . . . . . 21
INSTALLATION
INSTALLATION - FRONT (SRW) . . . . . . . . . . 22
INSTALLATION - REAR (SRW) . . . . . . . . . . . 22
INSTALLATION - FRONT (DRW) . . . . . . . . . . 22
INSTALLATION - REAR (DRW) . . . . . . . . . . . 22
SUPPORT PLATE
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION - REAR . . . . . . . . . . . . . . . . . . . 23
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS
PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 24
CABLE TENSIONER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
CABLES
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 24
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 25
INSTALLATION - REAR . . . . . . . . . . . . . . . . . 26
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 26
LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
SHOES
REMOVAL
REMOVAL - (SRW) . . . . . . . . . . . . . . . . . . . . 27
REMOVAL - (DRW) . . . . . . . . . . . . . . . . . . . . 27
CLEANING - REAR DRUM IN HAT BRAKE . . . . 28
INSTALLATION
INSTALLATION - (SRW) . . . . . . . . . . . . . . . . . 28
INSTALLATION - (DRW) . . . . . . . . . . . . . . . . . 28
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 28
BRAK ES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE SYS-
TEM
Base brake components consist of t he br ake pa ds,
calipers, brake dr um in h at rot or in the rea r, r otors,
brake lines, master cylinder, booster, and pa rking
brake com ponents.
Brake dia gnosis involves det erminin g if th e pr ob-
lem is related to a mechan ical, hydra ulic, or vacuum
operat ed component.
The first diagnosis step is th e preliminar y check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tir es an d wheels. Dam aged
wheels and wor n, damaged, or un derin flated t ires
can ca use pu ll, shudder, vibr ation, and a condit ion
simila r to gra b.
(2) If compla int wa s based on noise when br aking,
check suspension components. J ounce front and rear
of veh icle a nd listen for noise tha t m ight be ca used
by loose, wor n or dam aged suspension or steer ing
components.
(3) In spect br ake fluid level a nd condition. Note
that the brake reservoir fluid level will decr ease in
pr opor tion to normal lin ing wea r. Al so not e that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) If fluid level is abn orma lly low, look for evi-
dence of l eaks at calipers, wheel cylin ders, br ake
lin es, and m aster cylin der.
(b) If fluid appea rs contaminated, drain out a
sa mple to examine. System will ha ve to be flushed
if fluid is separ ated into layers, or cont ains a sub-
st ance ot her than br ake fluid. Th e system sea ls
and cups will also have t o be r eplaced after flush-
ing. Use clean br ake fluid to flush th e system .
(4) Check pa rking brake opera tion . Ver ify free
movem ent a nd full release of cables and pedal. Also
note i f vehicle wa s being operated wit h pa rking
br a k e pa r t ia lly a pplied.
(5) Check brake pedal opera tion. Verify that pedal
does not bind and ha s a dequat e free pla y. If pedal
lacks free play, check pedal an d power booster for
being loose or for bind condition. Do not r oad t est
until condition is correct ed.
(6) Check boost er vacu um check valve a nd hose.
(7) If componen ts checked appear OK, road t est
the vehicle.
ROAD TESTING
(1) If complain t involved low brake peda l, pump
peda l and note if it com es back up to nor mal heigh t.
(2) Check brake peda l respon se with transmission
in Neut ral and engine ru nnin g. Pedal should r emain
firm under constant foot pr essu re.
5-2 BRAKES- BASE VA
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