Attachment III - Technical Instructions
SAFETY RECALL 92S44TECHNICAL INSTRUCTIONS
BRAKE CALIPER PISTON INSULATOR KIT
INSTALLATION INSTRUCTIONS
1. Remove the front wheel and tire assemblies.
2. Remove the brake calipers from the rotors. Refer to the appropriate shop manual for the procedures.
3. Remove the inner and outer brake linings.
4. Inspect the brake caliper pistons.
If the pistons are phenolic, (brown in color) no modifications are required. Reassemble the calipers as described in the shop manual. If the truck is equipped with a 7.5L EFI engine, install the brake tube insulator kit. If the truck is not equipped with an 7.5L EFI engine, install the wheels and tires and release the truck.
If the pistons are aluminum, continue as described below.
5. Remove the steel retainer and Nomex thermal washers from the kit.
6. Place a steel retainer on a bench with the tabs facing up. Refer to Figure 1.
7. Place a Nomex thermal washer over the tabs so that it rests on the barb of each tab. Then, carefully press it over the barb of one of the tabs. Repeat the procedure for each of the remaining tabs.
NOTE:
Do not bend the tabs. The inner edge of the washer may crease slightly as it passes over the barb. This is permissible provided that the crease can be smoothed out once the washer is in place. The washer must be installed without tearing.
8. Push the washer down onto the back face of the retainer. Be sure it is seated uniformly on the retainer. Once installed, do not use an adhesive or other aid to hold it in place. This is neither necessary nor permissible.
9. Snap an assembled insulator into the inside diameter of each caliper piston. Be sure the assembly is firmly seated on the rim of the piston. See Figure 2.
10. Install the inner and outer brake linings.
11. Clean the caliper slide surfaces on the caliper and the spindle with a wire brush and lubricate with Disc Brake Caliper Slide Grease, D7AZ-19590-A (ESA-M1C172-A) or equivalent.
12. Reinstall the brake calipers. Refer to the appropriate shop manual for the procedures.
13. Install the wheel and tire assemblies.
BRAKE TUBE INSULATOR JACKET KIT
INSTALLATION INSTRUCTIONS
On trucks equipped with 7.5L EFI engines, wrap and fasten the insulator jackets (from kit) around the front brake tubes in the areas shown in Figure 3. Be sure the insulators are assembled with the opening facing away from the exhaust manifold whenever possible.
NOTE:
Use all four (4) insulators on trucks built before approximately December 1, 1989. On trucks built after approximately December 1, 1989, the tee block was deleted and lines 1 and 3 rerouted. Therefore, only brake tubes 2 and 4 will require the insulators.