Diesel Data: Automotive Repair

Rear

WARNING:
- Never use an air hose or dry brush to clean brake assemblies.
- Use an OSHA-approved vacuum cleaner to avoid breathing brake dust
.

1. Block the front wheels, loosen the rear wheel nuts slightly, support the rear of the vehicle on safety stands, then remove the rear wheels.

Caliper Shield Removal:





2. Release the parking brake, and remove the caliper shield.





3. Remove the brake hose clamp bolt from the trailing arm first, then remove the two caliper mounting bolts and the caliper from the bracket.

CAUTION:
- Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
- Support the caliper with a piece of wire so that it does not hang from the brake hose.

NOTE: Check the hoses and pin boots for damage or deterioration.





4. Remove the outer pad shim, pads, and pad retainers.

Checking Pad Thickness:





5. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include the pad backing plate thickness.
6. If the pad thickness is less than the service limit, replace the pads and shims together as a set.
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
8. Check the brake disc for damage and cracks.





9. Make sure that the pad retainers are installed in their correct positions.





10. Apply grease to the points indicated by the arrow in the following drawing:

NOTE: Use the pad grease included in the pad set or Molykote M77 grease, and apply a thin coat of grease evenly to the designated points.

- Piston end and inner pad contact surface
- Pad and caliper bracket contact surface
- Outer pad shim and outer pad contact surface
- Outer pad shim and caliper body contact surface

11. Install the brake pads and outer pad shim on the caliper bracket. Install the inner pad with its wear indicator facing downward.

WARNING:
- When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.
- Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads
.





12. Rotate the caliper piston clockwise into the cylinder, then align the cutout in the piston with the tab on the inner pad by turning the piston back.

CAUTION: Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it sits properly.

13. Install the brake hose clamp on the trailing arm.
14. Install and tighten the caliper mounting bolts.

Removing Caliper Shield:





15. Install the caliper shield.
16. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
17. Depress the brake pedal several times to make sure the brakes work, then test-drive.

NOTE: Engagement of the brake may require greater pedal travel immediately after the brake pads have been replaced as a set. Several light applications of the brake pedal will restore the normal pedal travel. Greater than normal pedal travel may damage the master cylinder.