Removal/Installation

Fig. 3 Disabling Parking Brake Automatic Adjuster Mechanism:

Fig. 1 Exploded View Of PBR Single Piston Rear Caliper:

Fig. 4 Parking Brake Free Travel Adjustment:

REMOVAL
1. Disable parking brake automatic adjuster as follows:
a. Working from inside vehicle, remove driver seat cushion, then the parking brake lever cover screws and cover.
b. Using 0.080 inch gauge wire, fabricate a tool to disengage drive pawl from sector, Fig. 3.
c. Using tool mentioned above, disengage drive pawl from sector, then insert a nail through anchor plate to keep drive pawl in disengaged position.
d. Pull up on lever until it aligns with pawl, then depress button until lever is fully downward.
e. Visually inspect that anchor plate is fully against stud. If not, repeat procedure as needed.
f. Pull front parking brake cable rearward to slacken cable at caliper assembly.
2. Raise and support vehicle, then remove tire and wheel assembly.
3. Install two wheel retaining nuts to retain rotor in position.
4. If caliper requires overhaul, remove inlet fitting attaching bolt, then disconnect inlet fitting from caliper housing. Discard the two gaskets, then plug openings in inlet fitting and caliper to prevent loss or contamination of fluid.
5. Remove caliper lever return spring. Discard spring if coils are open.
6. Disconnect parking brake cable from lever (5) and caliper bracket (8), Fig. 1.
7. Remove upper and lower guide pin bolts, then remove caliper from rotor and mounting bracket. If caliper does not require overhaul, suspend it from suspension to prevent damage to brake line.


INSTALLATION
1. Install shoe and lining assemblies, if removed, as outlined previously.
2. Position caliper over rotor and onto mounting bracket, then install upper and lower guide pin bolts. Torque upper bolt to 26 ft. lbs. and lower bolt to 16 ft. lbs.
3. Attach parking brake cable to caliper bracket and lever, then install lever return spring.
4. If removed, install inlet fitting using new gaskets, then bleed brake system.
5. If caliper was overhauled, adjust parking brake free travel as follows:
a. Have an assistant apply a light load to brake pedal until rotor can no longer be turned by hand.
b. Apply pressure to caliper lever in direction shown in Fig. 4.
c. Measure free travel between caliper lever and housing. Free travel should be 0.024-0.028 inch. If free travel is not as specified, proceed to next step.
d. Remove adjustment screw, then clean thread adhesive from threads.
e. Coat threads with new adhesive, reinstall adjustment screw, then turn as required until specified free travel is obtained. Turning screw clockwise increases free travel, while counterclockwise rotation decreases travel.
f. Release brake pedal, then firmly apply brake pedal three times and recheck free travel. Repeat adjustment procedure as necessary.
6. Remove nail from anchor plate installed during caliper removal procedure.
7. Apply and release parking brake three times, then lift lever upward and ensure parking brake fully engages at 7-9 clicks.
8. Release parking brake. No brake drag should exist and no gap between caliper housings and parking levers should be evident.
9. Install parking brake lever cover, screws and driver's cushion.
10. Reinstall tire and wheel assembly, then check and refill master cylinder as required.
11. Start engine and pump brake pedal several times to seat brake linings.