Caliper Assembly

Fig. 1 Exploded View Of Delco-Moraine 7735 Series Rear Caliper:

1. Install bleeder screw.
2. If removed, install bracket (5) and bolt (4), Fig. 1, then tighten bolt to specifications.
3. Lubricate piston seals and bore grooves with new brake fluid, then roll piston seal into seal groove in bore, ensuring seal is fully seated and not twisted.
4. Lubricate piston locator with new brake fluid, then position locator on piston using piston locator installer tool No. J-36627 or equivalent.
5. Install thrust washer on actuator screw, with grayish side towards caliper housing, then install lubricated shaft seal onto actuator screw.
6. Install actuator screw into piston assembly.
7. Install balance spring in piston recess in housing.
8. Install piston assembly, pressing piston in until locator is past retainer groove, turn actuator screw as necessary to allow piston assembly to move toward bottom of caliper bore, then install retainer ring.
9. Install lubricated dust boot over piston with inside lip in groove in piston and boot fold toward end of piston that contacts brake shoe, then bottom piston in caliper bore.
10. Install lubricated lever seal over end of actuator screw, ensuring seal bead is against caliper housing.
11. Install parking brake lever over actuator screw, rotate lever away from stop, then hold lever and torque retaining nut to 32 ft. lbs. After tightening retaining nut, rotate lever back to stop.
12. Seat dust boot in caliper counterbore using suitable driver.
13. Install shoe retainer in groove on end of piston, ensuring retainer tabs are properly aligned with piston notches.

Fig. 4 Bolt Boot & Sleeve Installation:

14. Install sleeves and bolt boots into caliper housing as follows:
a. Lubricate sleeves, bolt boots and caliper mounting bolt holes with silicone based grease.
b. Install one bolt boot into groove in mounting bolt hole of caliper housing.
c. Push sleeve into mounting bolt hole, past inner diameter of bolt boot, and position as shown in view A of Fig. 4.
d. Install second bolt boot in groove at other end of mounting bolt hole as shown in view B of Fig. 4.
e. Push sleeve in opposite direction until grooves of sleeve seat in inner diameter of both bolt boots as shown in view C of Fig. 4.
f. Repeat steps b through e to install remaining bolt boots and sleeve.
15. Install caliper as outlined further on.