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s·.
Install the
stabilizer
to anchor
plate attaching screws and tighten
finger tight.
9. Remove
the cap from the
brake hose
fitting.
Install a new
copper washer on each side of the
hose fitting
and
install the brake hose
on the caliper.
Tighten
the
attaching
screw to
27-32lbs.
ft. torque.
Bleed the brake system as
detailed
on Page
2-3
of this manual.
10.
Fill the master
cylinder
as re-
quired
to within 3/8 inch of the top
of
the
reservoir.
11.
With
moderate pressure
appli-
ed to the brake
pedal torque
the
stabilizer
attaching
screws to 8-20 lb
ft. and the caliper locating pins to
26-50 lb. ft.
12.
Install the wheel and tyre
assembly and
tighten
the wheel nuts
to 70-115
lbs.
ft. torque.
13. Pump the brake pedal
prior
to
moving the vehicle to
position the
brake pads.
DISC BRAKE CALIPER OVER-
HAUL AND BRAKE SHOE RE-
PLACEMENT P.B.R.
DISASSEMBLY
(1)
Remove
outboard
shoe by
pressing
down towards inboard shoe
at the same time
sliding forward.
(2)
Remove
inboard
shoe by slid-
ing away from
caliper piston.
At the
same time
overcoming
the
resistance
of the
anti-rattle
spring
attached
to the
shoe.
(3)
Mount the
caliper
in a vice
equipped
with
padded
jaws.
(4)
Remove
two cotter pins
retaining guide
pins.
(5)
Tap
out guide pins using a
suitable
pin
punch.
Note
Drive
guide
pin
out from cylinder
or inboard side of caliper.
( 6)
Tension on anti-rattle
spring
will then
be
relieved
and
spring can
be
removed
from anchor
bracket hold·
ing point.
(7)
Remove anchor
bracket
and
remaining
guide
and
anti-rattle
spring.
Clamp bracket
in vice.
(8)
Using screw
driver remove
anti-rattle spring
from anchor bracket
and
guide.
(9)
Remove
the four guide
pin
boots and discard. Check guide
pins
for wear and
plating damage. Replace
guide sleeve pin assy.
if damaged.
(10)
Remove
piston
by applying
compressed
air
at the
fluid inlet port
of the
caliper
taking
care
not
to
apply
air
at too high a
pressure
as to
cause the piston to l)Op out and
PART
2-2-BRAKE SYSTEM
2-23
damage
it
against
the
outboard
portion
of the caliper. A thin block
of wood or
hardboard
located in the
position
of the
outboard
shoe will
assure the piston is not
damaged.
(11) As
the piston
slides out, the
I.D. of the rubber boot in the
groove
of the
piston
should
stretch out
around
the large portion
of the pis-
ton
allowing
the piston to slide out
and be
removed.
(12) Peel boot out of
cylinder
groove and
discard.
(13)
Inspect
the piston for scor-
ing,
pitting, corrosion or
areas where
the chrome
plating is worn
off. If
any
damage is evident, replace
the
piston. If
not wipe clean
and set
aside. Black stains,
if
any,
are caused
by the seal and
will
do no
harm.
(14) Use a small
pointed
"wood
or
plastic
tool to remove the pis·
ton seal from its
groove
in the
cy-
linder bore and
discard,
be
careful
to avoid
damaging ·the seal
seat.
(15)
Clean all
parts with brake
fluid
and wipe dry with lint free
cloth, using
an
air
line, blow out
the drilled passages
and cylinder bore.
ASSEMBLY
(1)
Place
caliper assembly on
a
clean bench area with the open end
of
cylinder
up.
(2)
Dip
new piston seal in clean
disc
brake
fluid
and
install in cy-
linder groove.
Position
seal at
one
area in the
groove and gently
work
around
cylinder bore with a f'lllger
until
properly
seated. Check
to
be
sure
the seal
is not twisted or
rolled
in its
groove.
·
(3)
Coat
piston
boot in
P.B.R.
rubber grease. Place
piston boot
over
end
of piston.
(4)
Locate boot into groove in
caliper
bore.
(5)
liberally
coat
the
out-
side
diameter of
piston with
P.B.R.
rubber grease.
(6)
Position piston over cylinder
and press
the
piston straight into the
cylinder
until it
bottoms.
Use ex-
treme care not to scratch the
piston
or tear the dust boot. The
boot I.D.
should slide up the piston
as
the
piston moves into the
cylinder
and
comes to rest in the
piston groove.
(7)
Smear the
inside of the guide
pm
sleeve
with
Approved
High
Melting
Point Grease
-
refer specifications.
(8)
Smear the four
guide pin
boots with High
Melting Point grease
and
assemble
into
sleeve with the
lips
facing outwards.
(9)
Locate
fmt of guide pin
sleeves in
position.
(10) Line up sleeve with holes
in the caliper
assembly
and insert
guide pin using
care not to
damage
boots. Place drift
on to head
of pin
and
tap
pin into
position
with
hammer.
The
pin
must
be entered
from the
outboard
hole, i.e. The hole which
is not cross drilled to take a cotter
pin.
Note
Assemble
guide
pin
with narrow
rounded groove
at
cotter
pin
end.
(11) Place bracket
in
position
with
hook
end at the same end as the
bleeder screw. Insert second sleeve
and guide pin as above. Insert two
split cotter
pins
to retain guide
pin.
(12)
With the
aid of
expanding
circlip pliers
install the single loop
anti-rattle
spring over the guide pin
sleeve.
(13) Place a thin piece of shim
material
over sleeve. Locate double
loop anti-rattle spring and press spring
over sleeve.
Remove
shim
material.
Note
It
is
important
to
ensure
that the
guide
pin sleeve
is not burred or
scored
during installation
of
anti-rattle
springs. Burring of
the sleeves could
prevent automatic
pad
adjustment
when compensating.for
lining wear.
l14)
Slide inboard shoe towards
caliper piston,
at the same time locate
anti-rattle spring
inside
caliper piston.
( 15) Using
a screw driver to raise
retaining
clip slide one end of out-
board shoe
onto caliper housing.
Repeat
to place remaining
end
in
p<;>sition.
Ensure the two
locating
posts
locate in the two holes in
Caliper housing.
DUAL MASTER CYLINDER
DISASSEMBLY
1.
Clean the outside of the master
cylinder
and remove the filler cover
and
diaphragm. Pour
out any brake
fluid
that
remains in the
cylinder.
Discard
the old brake fluid.
2. In
the case of drum brake
vehicles,
prise up the two lugs on the
retaining plate
at the rear of the
master
cylinder
(Fig. 25). If the
secondary
piston
stop bolt
has not
been
removed
from
the
bottom of
primary
reservoir (Fig. 24) depress
the
primary
piston and remove the
stop bolt.
3. Remove
the
primary piston
assembly
from the master
cylinder
bore. Do not remove the screw
that retains the primary return
spring retainer, return spring
and protector on the primary
piston. This assembly
is
factory
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