Except Convertible

REMOVAL

1. Remove approximately 2/3 of brake fluid from master cylinder.
2. Raise and support vehicle.
3. Mark relationship between front wheel and axle, then remove wheel and tire assembly.
4. If caliper assembly is to be serviced, remove inlet fitting attaching bolt, copper washer, and inlet fitting from caliper housing. Plug opening in inlet fitting to prevent fluid loss and contamination. Do not crimp brake hose, as this may damage internal structure of hose. If only shoe and lining assemblies are to be replaced, do not disconnect brake line fitting from caliper.
5. Remove caliper mounting bolts.
6. Remove caliper from knuckle. Be careful not to drop inside pad which will come off with caliper.

DISASSEMBLY

Fig. 1 Exploded View Of Brake Caliper:

1. Remove caliper assembly as outlined previously, then drain brake fluid from caliper.
2. Remove cylinder boot set ring and boot from cylinder groove, Fig. 1.
3. Use clean shop towels to pad interior of caliper assembly, then remove piston by directing compressed air into caliper brake hose inlet hole. Use just enough air pressure to ease piston out of bore. Do not place fingers in front of piston for any reason when applying compressed air. This could result in serious personal injury.
4. Using a small piece of wood or plastic, remove piston seal from bore. Do not use a metal tool of any kind to remove seal as it may damage bore.
5. Remove bleeder valve.
6. Inspect piston for scoring, nicks, corrosion, and wear and replace as needed.
7. Inspect caliper housing and seal groove for corrosion, nicks, scoring and excessive wear, and use crocus cloth to polish away corrosion from housing bore. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth.
8. Clean all parts with denatured alcohol. Dry with unlubricated compressed air. Blow out all passages in housing and bleeder valve.

ASSEMBLY & INSTALLATION

Fig. 5 Installing Caliper Boot:

1. Apply suitable grease to piston seal and cylinder wall, then install the seal. Check to ensure piston seal is not twisted.
2. Install new boot on piston so side with 2 grooves faces in toward cylinder and side with 3 grooves faces out, Fig. 5.
3. Install piston in caliper so it projects about .4 inch to ease installation of boot on caliper housing. Install boot on caliper housing, then install set ring.
4. Install bleeder valve.
5. Check that caliper slide bushings are lubricated with rubber grease. Check that slide bushing in each carrier hole can be moved smoothly in each direction.
6. Install caliper and inside pad on knuckle.
7. Tighten caliper bolts.
8. Connect brake hose, then bleed hydraulic system.
9. Install wheel.
10. Lower vehicle and test brakes. Before moving vehicle, pump brake pedal several times to be sure it is firm. Do not move vehicle until a firm pedal is obtained.