Installation

***THIS ARTICLE INCLUDES CHANGES MADE BY TSB # 85-5-1, DATED DECEMBER 1984***

Lubricating Caliper Cavity:

1. Fill both cavities in housing between bushings with silicone grease.
2. Install sleeves in caliper.
3. Position caliper assembly over disc and align mounting bolt holes. If brake hoses were not disconnected during removal, use care not to kink hoses during installation.

Caliper Mounting Bolts:

4. Install mounting bolt/sleeve assemblies and torque to 51 Nm (38 ft. lb.).

Checking Clearance Between Caliper & Stops:

5. Check the dimensions between each caliper stop and caliper.

NOTE: The clearance at the end of the caliper should be measured individually and added together to determine the total caliper to knuckle clearance. The total clearance should be 0.26 - 0.60 mm (0.010 - 0.024 in.). If necessary remove caliper and file ends of bracket to provide proper clearance.

Front Brake Hoses:

6. If brake hose inlet fitting was disconnected during removal, install and torque to 45 Nm (33 ft. lb.).
7. Fill master cylinder. Bleed caliper if brake hose inlet fitting was disconnected and recheck master cylinder fluid level. Service and Repair
8. After installation of calipers, perform clinching procedure as described below:
a. Firmly apply brake pedal three times to ensure caliper piston is extended and shoes are fully seated.

Clinching Procedure Step 1:

b. Wedge a large flat blade screwdriver between outboard shoe flange and hat section of rotor. Pry up on outboard shoe.
c. Hold outer shoe against caliper with suitable clamp or by applying moderate pressure on brake pedal.

Clinching Procedure Step 2:

d. Position a ball peen hammer on outboard shoe tab, then using a larger brass hammer, lightly tap the ball peen hammer to bend the outboard shoe tab. Tabs must be bent around casting to approximately 45°.
e. After both tabs have been bent, pressure should be released and the outboard shoe should be locked into position. If the shoe is loose, repeat steps a. through d.

NOTE: If an outboard shoe is removed from the caliper, or the tabs unclinched for any reason, then it will be necessary to replace the shoe and lining assemblies. Do not re-clinch outboard shoe locking tabs after having removed shoe from caliper.

9. Remove wheel nuts securing rotor to hub and bearing assembly.
10. Install wheel and tire assembly aligning previous marks, then lower vehicle and torque wheel nuts to 140 Nm (100 ft. lbs.).

CAUTION: Before moving vehicle, pump brake pedal several times to be sure it is firm. Do not move vehicle until a firm pedal is obtained.

For additional information see Removal Notes. Fundamentals and Basics