Caliper Removal and Installation
RemovalWARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators.
WARNING: Occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. CAUTION: Install new brake pads in complete axle sets.
Inspect the brake pads for wear or contamination.
^ Install new brake pads if worn to or past specification.
4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
Disconnect the brake hose.
1. Remove the bolt.
2. Disconnect the rear wheel brake hose.
3. Remove the copper washers, and plug the brake hose.
5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubricating the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
Remove the rear disc brake caliper.
1. Remove the brake caliper bolts.
2. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
6. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
7. Measure the brake disc thickness.
^ Install a new brake disc if not within specification.
Installation
1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt.
Note: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged.
Note: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.
Install the rear disc brake caliper.
2. Install the rear wheel brake hose.
^ Use new copper washers; connect the brake hose and install the caliper flow bolt.
3. Bleed the rear disc brake caliper.
4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel, wheel hub, or brake disc. Any foreign material on the wheel mounting surfaces can cause the wheel nuts to loosen and come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting surface.
5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch.
Install the wheel and tire assembly.
6. Verify correct brake operation.