Removal and Installation

Fig. 3 Parking Lever & Cable Installation:

Fig. 4 Rear Caliper Assembly Removal:

Fig. 5 Adjusting Piston Depth For Lining Installation:

Fig. 6 Disc Brake Tool Modification:

Removal

1. Raise vehicle and support on safety stands, then remove tire and wheel assemblies.
2. Disconnect fitting on rear brake tube from hose end fitting at frame mounted bracket and plug end of brake tube to prevent loss of fluid and entry of dirt. Remove horse shoe retaining clip from hose fitting and disengage hose from bracket.
3. Disconnect parking cable from lever, Fig. 3, using care to avoid kinking or cutting cable or return spring, then remove retaining screw from caliper retaining key, Fig. 4, then remove caliper locating pins.
4. Slide caliper retaining key and support spring from anchor plate, Fig. 4. If necessary, use a hammer and brass drift, being careful to avoid damaging key on sliding ways or hitting parking brake lever. If caliper cannot be removed due to rust build-up on outer edge of rotor, scrape off loose scale, being careful not to damage braking surfaces. If rotor wear or scoring prevents removal of caliper, it will be necessary to loosen caliper end retainer 1/2 turn maximum, to allow piston to be forced back into its bore. To loosen end retainer, remove parking brake lever and mark or scribe end retainer and caliper housing to be sure that end retainer is not loosened more than 1/2 turn, then force piston back in its bore, Fig. 5, and move caliper back and forth to center rotor and remove caliper. If retainer must be loosened more than 1/2 turn, use caution, as the seal between the thrust screw and housing may be broken and brake fluid will enter parking brake mechanism chamber. In this case, the end retainer must be removed and the internal parts cleaned and lubricated.
5. Remove outer shoe and lining assembly from anchor plate, then remove rotor retainer nuts and rotor from axle shaft.
6. Remove inner brake shoe and lining assembly from anchor plate and mark each shoe for identification if they are to be reused.
7. Remove anti-rattle clip from anchor plate, then remove flexible hose from caliper by removing hollow retaining bolt.

Cleaning & Inspection

Clean caliper, anchor plate and rotor assembly and inspect for signs of brake fluid leakage, excessive wear or damage. The caliper must be inspected for leakage both in piston boot area and operating shaft seal area. Lightly sand or wire brush any rust or corrosion from caliper and anchor plate sliding surfaces and inner brake shoe abutment surfaces in anchor plate. Inspect brake shoes for wear. Linings must not be worn to within less than 1/8 inch of shoe surface.

Installation

1. If end retainer has been loosened only 1/2 turn, reinstall caliper in anchor plate using key. Do not install shoe and lining assembly. Torque end retainer to specification, then install parking brake actuating lever on its keyed spline. Lever arm must point down and rearward so that parking brake cable will pass freely under axle. Torque retainer screw to specification. Parking brake lever must rotate freely after torquing retainer screw.
2. Remove caliper from anchor plate. If new shoe and lining assemblies are to be installed, the piston must be bottomed in caliper bore using tool No. T75P-2588-B to provide clearance. Remove rotor and install caliper without lining and shoe assemblies in anchor plate using key only. Install tool and while holding shaft, rotate tool handle counterclockwise until the tool seats firmly against piston, Fig. 5. Loosen handle about 1/4 turn, and while holding handle rotate tool shaft clockwise until piston is fully bottomed in bore (piston will continue to turn even after it is bottomed). Turn tool handle until there is no further inward movement of piston and there is a firm seating force, then remove caliper from mounting plate and reinstall rotor. For use on some vehicles, tool No. T75P-2588-B must be slightly modified, Fig. 6.
3. Making certain that brake shoe anti-rattle clip is in place in lower inner brake shoe support on anchor plate with loop of clip toward inside of anchor plate, Fig. 4, position inner brake shoe and lining assembly on anchor plate, then install rotor and two retaining nuts.
4. Install outer brake shoe with lower flange ends against caliper abutments and brake shoe upper flanges over shoulders on caliper legs. The shoe upper flanges fit tightly against machined shoulder surfaces. If old brake shoes and lining assemblies are reused, be certain the shoes are installed in their original positions as marked for identification during removal.
5. Lubricate caliper and anchor sliding ways with D7AE-019590 grease, using care to prevent lubricant from getting on braking surfaces, then position caliper housing lower V-groove on anchor plate lower abutment surfaces.
6. Rotate caliper until it is completely over rotor, being careful not to damage piston dust boot, then pull caliper outboard until inner shoe and lining is firmly seated against rotor. Measure clearance between outer lining and rotor, clearance must be between 1/32 and 3/32 inch. If it is greater, remove caliper and move piston outward to narrow gap. Follow procedure in step 2 and note that 1/4 turn of the shaft counterclockwise, moves piston about 1/16 inch. A clearance greater than specified limit may allow adjuster to be pulled out of piston when service brake is applied, causing parking brake to fail to adjust. It will then be necessary to replace piston/adjuster assembly.
7. While holding caliper against anchor plate upper abutment surfaces, center caliper over lower anchor plate abutment, then position caliper support spring and key in slot and slide them into opening between lower end of caliper and lower anchor plate abutment until key semi-circular slot is centered over retaining screw threaded hole in anchor plate.
8. Install key retaining screw and torque to specification, then reinstall brake hose on caliper. Place a new gasket on each side of the fitting outlet, then install the attaching bolt through the washers and fitting and torque to specification.
9. Lubricate pins and inside of insulator with D7AZ-19A331-A or equivalent silicone grease and add one drop of Loctite EOAC-19554-A, or equivalent, to locating pin threads. Install locating pins through caliper insulators and into anchor plate and torque to specification.
10. Connect parking brake lever to lever on caliper.
11. Perform system brake bleeding procedures, then with engine running pump brake pedal lightly about 40 times allowing 1 second between pedal applications. An alternate with engine off is to pump brake pedal lightly about 10 times to discharge accumulator, then pump brake pedal firmly about 30 times. Check parking brake for excessive travel or very light effort, if so, repeat pumping brake pedal, and if necessary check parking brake cable tension.
12. Install wheel and torque nuts to specification. Before moving vehicle, make certain that a firm brake pedal has been obtained.