5D-2
1968
PONTIAC
SERVICE
MANUAL
6.
Reinstall
shoe
retaining pin through outboard
caliper
half, outboard shoe, inboard
shoe
and inboard
caliper
half. Place a new, 3/32" x 5/8" stainless
steel cotter pin through retaining pin and lock. Re-
move piston retaining clips.
7. Repeat
steps
2 through 6 at other front wheel.
8.
Install
wheels and tighten wheel nuts to 75 lb. ft.
(Pontiac),
70 lb. ft. (Tempest and
Firebird).
9.
Lower
hoist or remove
jack
stands.
10.
Check
master cylinder fluid level and
fill,
if
necessary. Depress brake pedal several times to
seat linings on disc.
Re
check
master cylinder fluid
level and
refill,
if necessary. If brake pedal
feels
spongy, bleed brakes.
CAUTION:
Do not move car until a firm brake
pedal
is obtained.
BRAKE DISC-REMOVE
1. Raise car and remove front wheels.
2. Remove brake
hose
support to caliper mounting
bracket
screw.
3.
Remove caliper to mounting bracket bolts. Hang
caliper
from upper suspension.
NOTE:
Do not place
strain
on brake hose.
4. Remove spindle nut and disc and hub assembly.
BRAKE DISC-INSTALL
1.
Install
new bearings or seal as necessary.
2.
Install
hub and disc assembly on spindle. See
Section
3
-
Front
Suspension for Wheel Bearing
Adjustment
Procedure.
3.
Install
caliper and tighten bolts to 60 lb. ft.
Mount tube support bracket and tighten bolt to 27 lb.
ft. (Pontiac), 17 lb. ft. (Tempest and
Firebird).
4. Mount wheel and tighten wheel bolt nuts to 75
lb.
ft. (Pontiac), 70 lb. ft. (Tempest and
Firebird).
Lower
hoist or remove jackstands.
5. Depress brake pedal several times to seat
linings on disc.
CA
UTION:
Do not move car until a firm brake
pedal
is obtained.
DISC
BRAKE CALIPER
OVERHAUL
CALIPER—REMOVE (Fig.
5D-6)
1. Disconnect brake line tube nut from inboard
caliper
side of the calipers. Plug end of tube to
prevent entrance of dirt and
loss
of fluid.
2. Detach caliper assembly from mounting bracket
by removing two hex head bolts and take to clean
work
area.
CALIPER-DISASSEMBLE
1. Remove and discard cotter pin from inboard end
of
shoe
retaining pin, slide out retaining pin and
remove shoes. If old
shoes
are to be reused, they
should be marked for proper installation at time of
assembly.
Clean
outside of caliper with a reputable
cleaner or clean denatured alcohol.
2. Separate caliper halves by removing two large
hex head bolts. Remove two small O rings from
cavities around fluid transfer
holes
in both ends of
outboard caliper halves.
3.
To free piston
boots
so pistons may be re-
moved, push piston down into caliper as far as it
will
go. Insert a screwdriver blade under inner
edge
of steel ring in
boot
and using piston as a fulcrum,
pry
boot
from its seat in caliper half. (Fig. 5D-2)
CAUTION:
Do not damage cylinder bore
during
disassembly
of boot.
4. Remove piston assemblies and springs from
caliper
half. Remove
boot
and seal from piston,
INSPECTION
AND
CLEANING
OF
CALIPER
Inspect
cylinder bore for scoring pr corrosion. If
cylinder
bore is corroded, the caliper half should be
replaced.
NOTE:
Staining is not to be confused with cor -
rosion.
Corrosion
can be identified as pits or
excessive
roughness.
Polish
any discolored or stained area with crocus
cloth by rotating the cloth supported by a finger in
the bore. Do not slide the cloth in or out of bore
under
pressure. Do not use any other form of
abra-
sive
or abrasive
cloth.
Clearance
of piston in bore as checked using a
feeler
gage
should be .0045" to .010".
All
rubber parts,
boots,
seals and O-rings, should
be replaced with new parts. All rubber parts are
contained in repair kit.
Use a reputable cleaner or denatured alcohol to
remove all traces of dirt or grease. Do not use
mineral
base solvents to clean brake parts. Using
an
air hose, blow out all fluid passages in caliper
halves, making sure that there is no dirt or foreign
material
blocking any passage. During reassembly,
use care to keep dirt out of caliper assembly.
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