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CHAPTER 32

CHAPTER 32. Disc Brake System. Removing and Inspecting Calipers. 32-1. Research the procedure for removing the caliper in the appropriate service information. Loosen the bleeder screws slightly and then retighten them. Removing and Inspecting Calipers. 32-1.

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CHAPTER 32

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  1. CHAPTER 32 Disc Brake System

  2. Removing and Inspecting Calipers 32-1 • Research the procedure for removing the caliper in the appropriate service information. Loosen the bleeder screws slightly and then retighten them.

  3. Removing and Inspecting Calipers 32-1 • If the caliper is being rebuilt or a new caliper will be installed, it is good practice to flush the old brake fluid from the system at this time.

  4. Removing and Inspecting Calipers 32-1 • Use a brake pedal holding tool to slightly apply the brakes and block off the compensating ports in the master cylinder to avoid excess fluid leakage.

  5. Removing and Inspecting Calipers 32-1 • Remove the brake line or hose from the caliper. Be careful not to lose the sealing rings.

  6. Removing and Inspecting Calipers 32-1 • Push the caliper pistons back into their bores slightly. While many use a screwdriver as shown, a pry bar is a safer choice.

  7. Removing and Inspecting Calipers 32-1 • Remove the caliper assembly from its mountings.

  8. Removing and Inspecting Calipers 32-1 • Inspect the caliper for leaks or damage, including the piston dust boot. Determine any necessary actions.

  9. Inspecting Caliper Mountings,Slides, and Pins 32-2 • Clean the caliper mountings and slides/pins using equipment/procedures for dealing with asbestos/hazardous dust.

  10. Inspecting Caliper Mountings,Slides, and Pins 32-2 • Inspect the caliper mountings and slides/pins for wear and damage. Determine any necessary actions.

  11. Inspecting Brake Pads and WearIndicators 32-3 • Determine the type of wear indicator system utilized. Check that it is not contacting or nearly contacting the rotor.

  12. Inspecting Brake Pads and WearIndicators 32-3 • If the system is a sensor style, test the system to verify that the system is operational. Determine any necessary actions.

  13. Checking Brake Pads 32-4 • Remove the pads and retaining hardware. Inspect all pads, retaining hardware, and anti-noise shims for wear or damage.

  14. Checking Brake Pads 32-4 • Measure the remaining brake pad thickness and compare to specifications. Determine any necessary action(s).

  15. Disassembling Calipers 32-5 • Disassemble the caliper, following the service manual procedure.

  16. Disassembling Calipers 32-5 • Clean all of the caliper parts following the service manual procedure.

  17. Disassembling Calipers 32-5 • Inspect each of the parts for damage, rust, and wear.

  18. Disassembling Calipers 32-5 • Measure the caliper bore-to-piston clearance with a feeler gauge and compare to specifications. Determine any necessary actions.

  19. Reassembling Calipers 32-6 • Make sure the rotor has been properly installed on the hub/spindle and the hub surface is free of rust or dirt.

  20. Reassembling Calipers 32-6 • Reassemble the caliper assembly, following the manufacturer’s procedure.

  21. Reassembling Calipers 32-6 • Assemble the pads, hardware, and caliper on the caliper mountings using the specified lubricant. Lubricate all moving parts.

  22. Reassembling Calipers 32-6 • Reinstall the brake line fittings using two new copper washers (if equipped).

  23. Reassembling Calipers 32-6 • Tighten the brake line fitting and caliper bolts to the proper torque. Bleed the brakes following the manufacturer’s procedure.

  24. Reassembling Calipers 32-6 • Seat the pads by applying the brake pedal several times, not allowing the pedal to go all the way to the floor.

  25. Reassembling Calipers 32-6 • If the brake pedal is spongy, you will need to bleed the brakes of any remaining trapped air in the system.

  26. Reassembling Calipers 32-6 • Inspect the system for any brake fluid leaks, no matter how small.

  27. Retracting and Readjusting Pistonson an Integrated Parking Brake 32-7 • Research the procedure for retracting the caliper piston. Select the proper adapter or tool to match the caliper piston.

  28. Retracting and Readjusting Pistonson an Integrated Parking Brake 32-7 • Install the tool and turn it in the direction that causes the piston to retract.

  29. Retracting and Readjusting Pistonson an Integrated Parking Brake 32-7 • Continue turning until the piston is lightly seated at the bottom of its bore.

  30. Retracting and Readjusting Pistonson an Integrated Parking Brake 32-7 • Make sure the dust boot is seated properly in its grooves.

  31. Inspecting and Measuring DiscBrake Rotors 32-8 • Research the procedure and specifications for inspecting the rotor. If you have not already done so, remove the caliper assembly, brake pads, and any hardware. Clean the rotor with approved asbestos removal equipment.

  32. Inspecting and Measuring DiscBrake Rotors 32-8 • Inspect the rotor for hard spots or hot spots, scoring, cracks, and damage.

  33. Inspecting and Measuring DiscBrake Rotors 32-8 • Measure the rotor thickness at the deepest groove or thinnest part of the rotor and compare to specifications.

  34. Inspecting and Measuring DiscBrake Rotors 32-8 • Measure the thickness of the rotor in a minimum of five to eight places around the face of the rotor. Calculate the maximum thickness variation and compare to specifications.

  35. Inspecting and Measuring DiscBrake Rotors 32-8 • Set up a dial indicator to measure lateral runout. Rotate the rotor and find the lowest spot on the rotor, then zero the dial indicator.

  36. Inspecting and Measuring DiscBrake Rotors 32-8 • Slowly rotate the rotor to find the highest spot on the rotor. Read the dial indicator showing maximum runout.

  37. Inspecting and Measuring DiscBrake Rotors 32-8 • Keep turning the rotor to make sure the dial indicator does not read below zero. If it does, rezero the dial caliper on the lowest spot. Keep turning the rotor to find the highest spot and reread the dial indicator. Compare all of your readings to the specifications and determine if the rotor is fit for service, is machinable, or needs to be replaced.

  38. Removing and Reinstalling Rotors 32-9 • Research the procedure for removing and reinstalling the brake rotor. If you have not already done so, remove the caliper assembly, brake pads, and any hardware. If the caliper mount straddles the rotor, remove it.

  39. Removing and Reinstalling Rotors 32-9 • To remove the hubless-style rotor, mark the rotor for proper reinstallation.

  40. Removing and Reinstalling Rotors 32-9 • If there are screws or speed nuts holding the rotor to the hub, remove them.

  41. Removing and Reinstalling Rotors 32-9 • Remove the rotor from the hub.

  42. Removing and Reinstalling Rotors 32-9 • To remove the hub-style rotor, remove the wheel bearing locking mechanism.

  43. Removing and Reinstalling Rotors 32-9 • Remove the wheel bearing adjusting nut, thrust washer, and outer bearing.

  44. Removing and Reinstalling Rotors 32-9 • Follow the steps of the inner bearing and grease seal removal procedure if the rear bearing must be removed.

  45. Removing and Reinstalling Rotors 32-9 • To reinstall a hubless-style rotor, clean all mounting surfaces on the hub and rotor and remove any burrs.

  46. Removing and Reinstalling Rotors 32-9 • Slip the rotor over the wheel studs.

  47. Removing and Reinstalling Rotors 32-9 • If the rotor uses small screws to hold the rotor to the hub, reinstall those and tighten to the proper torque.

  48. Removing and Reinstalling Rotors 32-9 • Spin the rotor to ensure it spins true and does not contact any other components such as the dust shield.

  49. Removing and Reinstalling Rotors 32-9 • To reinstall a hub-style rotor, see the wheel bearing service skill drills in the Wheel Bearing chapter. Be sure to properly lock the adjustment nut in place once adjustment is completed.

  50. Removing and Reinstalling Rotors 32-9 • Spin the rotor to ensure it spins true and does not contact any other components such as the dust shield.

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