2-20 GROUP 2 - Brakes
to the brake pedal, torque the sta-
bilizer attaching screws and caliper
guide pins to specification.
DISC BRAKE CALIPER
ASSEMBLY
REMOVAL
1.
Remove the front wheel cover.
Remove the wheel and tire assembly
from the hub and rotor assembly.
Be careful to avoid damage or inter-
ference with the caliper splash shield
or bleeder screw fitting.
2.
Disconnect the brake line from
the caliper.
3.
Remove the safety wire and the
two bolts that attach the caliper as-
sembly to the spindle.
4.
Lift the caliper assembly off
the rotor and place it on the bench.
INSTALLATION
1.
Position the caliper assembly on
the rotor, and mate the mounting bolt
holes in the caliper with those in the
spindle. It may be necessary to push
the caliper piston into the cylinder
bore to obtain clearance between the
shoe and lining assembly and the ro-
tor.
2.
Install the caliper to spindle at-
taching bolts and torque them to spec-
ification. The upper bolt must be
tightened first. Install the safety wire
on the bolts and twist the wire ends
at least five turns. Check to insure
that the rotor runs squarely and cen-
trally between the two brake shoes.
3.
Position the brake hose fitting
with a new copper washer on each
side of the fitting on the caliper
assembly. Install the bolts and torque
to specification.
4.
Bleed the brake system and cen-
tralize the differential valve as out-
lined in Part 2-1. Check the master
cylinder fluid level and add the speci-
fied fluid, as required. Pump the brake
pedal several times to actuate the
piston seals and to position the shoe
and lining assemblies.
6. Install the wheel and tire assem-
bly and the wheel cover.
7.
Road test the vehicle.
FRONT WHEEL HUB AND
ROTOR ASSEMBLY—DISC
BRAKES
REMOVAL
1.
Remove the wheel and tire from
the hub. (Fig. 18). Be careful to avoid
damage or interference with the bleed-
er screw fitting.
2.
Remove the caliper assembly
from the spindle and the rotor. If the
caliper does not require servicing, it
is not necessary to disconnect the
brake hose or remove the caliper from
the vehicle. Position the caliper out of
the way, and support it with a wire to
avoid damaging the caliper or
stretching the hose. Insert a clean
cardboard spacer between the linings
to prevent the piston from coming
out of the cylinder bore while the
caliper is removed.
Handle the rotor and caliper as-
semblies in such a way as to avoid
deformation of the rotor and nicking
scratching or contamination of the
brake linings.
3.
Remove the grease cap from the
hub.
Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly.
4.
Remove the hub and rotor as-
sembly from the spindle.
INSTALLATION
1.
If the rotor is being replaced,
remove the protective coating from
the new rotor with carburetor de-
greaser. Pack a new set of bearings
with specified grease (M-1C75A), and
install the inner bearing cone and rol-
ler assembly in the inner cup. Pack
grease lightly between the lips of a
new grease seal and install the seal
(Fig. 18).
If the original rotor is being in-
stalled, make sure that the grease in
the hub is clean and adequate, that
the inner bearing and grease seal
are lubricated and in good condition,
and that the rotor braking surfaces
are clean.
2.
Install the hub and rotor assem-
bly on the spindle.
3.
Lubricate and install the outer
wheel bearing, washer and adjusting
nut.
4.
Adjust the wheel bearings to
specification, and then install the nut
lock, cotter pin, and grease cap. The
wheel bearing adjustment is especial-
ly important with disc brakes.
5. Mount the caliper assembly on
the spindle and torque the two at-
taching bolts to specification. The
upper bolt must be installed first. If
necessary, push the caliper piston into
the cylinder bore to obtain clear-
ance between the shoe and lining as-
semblies and the rotor. Be sure that
the shoe and lining assemblies are
seated on the bridges. Check the flex-
ible hose for correct routing.
6. Install the wheel and tire on the
hub.
7.
Pump the brake pedal as re-
quired to establish the proper pedal
height.
8. Fill the master cylinder to the
proper level with the specified fluid.
DISC BRAKE ROTOR SPLASH
SHIELD
REMOVAL
1.
Remove the caliper and the hub
and rotor assembly as outlined under
Removal in the foregoing procedure
(it is not necessary to disconnect hy-
draulic connections).
2.
Remove the three bolts that at-
tach the splash shield to the spindle
(Fig. 18).
INSTALLATION
1.
If the shield is bent, straighten it
out before installation. Position the
shield to the mounting bracket, install
the attaching bolts nuts, and torque
them to specification (Fig. 18).
2.
Install the hub and rotor assem-
bly and the caliper as outlined under
Installation in the foregoing proce-
dure.
PROPORTIONING VALVE
The proportioning valve is serviced
as an assembly and is never adjusted
or overhauled.
REMOVAL
1.
Disconnect and remove the dif-
ferential pressure valve to proportion-
ing valve brake tube. (Fig. 19).
2.
Disconnect the outlet brake
tube at the proportioning valve.
3.
Remove the bolt attaching the
proportioning valve to the bracket and
remove the valve.
INSTALLATION
1.
Position the proportioning valve
to the bracket and install the attaching
bolt.
2.
Connect the outlet brake tube
to the valve.
3.
Position and connect the differ-
ential pressure valve to proportioning
valve brake tube.
4.
Bleed the brake system and cen-
tralize the diffential valve. (Refer to
Part 2-1, Section 2 for the correct
procedure.)
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