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5D-2
1968 P O N T I A C 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 r e
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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