B
86
Repair and Service Manual
BRAKES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
634756
BRAKE MASTER CYLINDER FLUID
Hydraulic brake systems must be totally flushed if the
fluid becomes contaminated with water, dirt or other cor-
rosive chemicals.
Flush Hydraulic Brake System
Bleed the entire system until all brake fluid is removed.
Replace with fresh DOT 3 standard automotive brake
fluid.
Check Brake Fluid
The brake fluid should be checked at regular intervals (as
specified in the Periodic Service Schedule) or immedi-
ately if fluid leaks are found.
Clean the cap with a shop rag and remove the cap from
master cylinder.
Use a mechanics mirror and a flashlight to check fluid
level.
Add fluid if level is below 1/4" (6.5 mm) from the top of the
reservoir.
Inspect for visible fluid leaks.
ROUTINE MAINTENANCE
Tool List
Qty.
Shop Rag................................................................. A/R
Mechanics Mirror ......................................................... 1
Flashlight ..................................................................... 1
Transmission Fluid Funnel........................................... 1
Torque Wrench, ft. lbs.................................................. 1
Torque Wrench, in. lbs................................................. 1
Crows Foot 9/16", 3/8" drive........................................ 1
Open End Wrenches, 3/8",
1/2", 5/8", 9/16" ................ 1
Needle Nose Pliers...................................................... 1
Ratchet ........................................................................ 1
Sockets, 3/8",
1/2", 5/8", 9/16"..................................... 1
Micrometer/Vernier Caliper.......................................... 1
2" C Clamp .................................................................. 1
Floor Jack .................................................................... 1
Jack Stands ................................................................. 1
Ball Joint Seperator ..................................................... 1
Lug Wrench, 3/4" ......................................................... 1
Jack ............................................................................. 1
Jack Stands ................................................................. 4
Brake Adjusting Tool.................................................... 1
Plastic Faced Hammer ................................................ 1
Never work on a vehicle supported by a jack
alone. To prevent possible personal injury, the
vehicle must be supported on jack stands dur-
ing procedures that require lifting.
REPLACEMENT OF WEAR ITEMS
Wear a dust mask and eye protection working
on wheel brakes.
Do not use pressurized air to blow dust from
brake assemblies.
Brake Pad Replacement
Unless fluid is lost or a brake line is disconnected, there
is no need to bleed the system to replace brake pads.
Brake pads should always be replaced as a full set of
four pads.
Remove old brake pads:
Raise the vehicle per the SAFETY section.
Loosen both of the bolts securing the caliper to the spin-
dle but only remove one. Swing the caliper free from the
rotor.
Note the orientation of the brake pads for reassembly pur-
pose. Push out the two guide/retainer pins from the cali-
per and remove pads.
Install new set of pads:
Position the new pads in the same orientation as the ones
removed. If the pads have been correctly positioned, the
guide/retainer pins will easily engage. Reinsert the guide/
retainer pins, making sure they are correctly seated in the
grooves machined in the caliper casting.
Gently push the pads away from each other to provide
adequate clearance with the rotor and then swing the
entire caliper and pad assembly back over the rotor.
Secure the caliper to the spindle and tighten both bolts to
25 - 30 ft. lbs (33 - 40 Nm) torque.
