Rear Disc Brake Recall Info (Tech Article?)
06-24-2004, 02:11 AM
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Car: 1984 Z28 Hardtop
Engine: 383 Carb
Transmission: 4L60
Axle/Gears: 3.54 Dana 44
Rear Disc Brake Recall Info (Tech Article?)
Does anyone think this is worthy of a tech article?
<HR>
<TABLE>
<TR><TH ALIGN=RIGHT>Number:<TD>86C28
<TR><TH ALIGN=RIGHT>Section:<TD>5
<TR>
<TR><TH ALIGN=RIGHT>Date:<TD>June, 1991
<TR>
<TR><TH ALIGN=RIGHT>Subject:<TD>PRODUCT SAFETY CAMPAIGN 86C28 REAR DISC BRAKE CONE CLUTCH PARK BRAKE ADJUSTER
<TR><TH ALIGN=RIGHT>Model and Year:<TD>1982-86 CHEVROLET CAMAROS WITH REAR DISC BRAKES (RPO J65) AND MANUAL TRANSMISSIONS
<TR>
<TR><TH ALIGN=RIGHT>To:<TD>All Chevrolet Dealers
</TABLE>
<P>
The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.
If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.
To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.
<P>
<B>Defect Involved</B><BR>
General Motors has determined that a defect which relates to motor vehicle safety exists in 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions. These vehicles may exhibit a lack of park brake automatic adjustment leading to reduced parking brake effectiveness.
To correct this condition, all involved vehicles will have an improved design rear brake caliper actuator installed. Other repairs to restore park brake functions to proper operation may also be made in conjunction with this campaign.
<P>
<B>Vehicles Involved</B><BR>
Involved are 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions, and built within the following VIN breakpoints:
<P>
<TABLE BORDER=1>
<TR><TH>YEAR<TH>MODEL<TH>PLANT<TH>CODE<TH>FROM<TH>THROUGH
<TR><TD ALIGN=CENTER>1982<TD ALIGN=CENTER>F-Car<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>CN100001<TD ALIGN=CENTER>CN168020
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>CL123326<TD ALIGN=CENTER>CL221394
<TR><TD ALIGN=CENTER>1983<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>DN103234<TD ALIGN=CENTER>DN165071
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>DL100280<TD ALIGN=CENTER>DL168650
<TR><TD ALIGN=CENTER>1984<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>EN100002<TD ALIGN=CENTER>EN200276
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>EL100004<TD ALIGN=CENTER>EL260754
<TR><TD ALIGN=CENTER>1985<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>FN100008<TD ALIGN=CENTER>FN176201
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>FL100079<TD ALIGN=CENTER>FL503417
<TR><TD ALIGN=CENTER>1986<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>GN100007<TD ALIGN=CENTER>GN188639
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>GL100002<TD ALIGN=CENTER>GL203370
</TABLE>
<P>
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
<P>
<B>Owner Notification & Dealer Responsibility</B><BR>
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter).
Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.
<P>
<B>Parts Information</B><BR>
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
<P>
<TABLE BORDER=1>
<TR VALIGN=TOP><TH>Part Number<TH> Description<TH> Quantity/Vehicle
<TR VALIGN=TOP><TD>18019028<TD> Rear Brake Caliper Actuator Kit<BR>
Each Kit Contains:
<UL>
<LI>2 Actuator Assemblies
<LI>All Necessary Gaskets & Seals
<LI>2 Brake Pad Dampening Springs
</UL><TD> 1
<TR VALIGN=TOP><TD>12300230<TD> Brake Pads<TD> As Required
<TR VALIGN=TOP><TD>18010361<TD> Actuator Levers<TD> As Required
<TR VALIGN=TOP><TD>10200446<TD> Parking Brake Cable<UL><LI>Front</UL><TD> As Required
<TR VALIGN=TOP><TD>10200448<TD> Parking Brake Cable Kit (Both Rear Cables)<UL>
<LI>P/N 10200443 Left Rear Cable
<LI>P/N 10200444 Right Rear Cable</UL><TD> As Required
<TR VALIGN=TOP><TD>10046472<TD> Parking Brake Apply Handle<TD> As Required
<TR VALIGN=TOP><TD>10139097<TD> Banjo Washer<TD> As Required
<TR VALIGN=TOP><TD>01052535<TD> Brake Fluid<TD> 1 Pint
</TABLE>
<P>
DEALERS ARE TO RETURN ALL SERVICE INVENTORY OF SEAL KIT P/N 18010453, ACTUATOR KIT P/N 18016369, AND REAR CALIPER P/N 18016374. PLEASE IDENTIFY THESE PARTS AS SPECIAL RETURNS ON YOUR PC659 DOCUMENT.
<P>
<B>Service Procedure</B><BR>
<B>A.</B> Raise vehicle and remove both rear tire/wheel assemblies.
<P>
<B>B.</B> Inspect park brake apply system for proper function, corrosion, kinks, etc. Remove nonfunctional cables.
<P>
<B>C.</B> Spray equalizer and both bleeder screws with Liquid Wrench (or equivalent product). Do not remove screws at this time.
<P>
<B>D.</B> Remove both rear calipers following the procedures in the appropriate Service Manual.
<P>
<B>E.</B> Remove brake pads.
<P>
<B>F.</B> Inspect brake pads for taper wear or excessive wear. Taper wear can be determined by taking measurements at the four points shown in the diagram below.
<P>
<IMG SRC="http://members.shaw.ca/crussel/brake_pad.gif">
<P>
Calculate pad taper by subtracting the thinnest point measured from the thickest point measured.
The brake pads should be replaced if taper is greater than .080 inches.
<P>
<B>G.</B> Overhaul calipers as follows:
<P>
Tools Required:
<TABLE BORDER=1>
<TR><TD>J-22269-01<TD>Piston Installer
<TR><TD>J-38898<TD>Boot Seal Installer
</TABLE>
<P>
1. Remove shoe damping spring from end of piston. <BR>
2. Remove park brake lever. <BR>
3. Remove lever seal and antifriction washer. <BR>
4. Remove piston by turning actuator screw with lever or wrench. <BR>
<B>NOTICE:</B> DO NOT REUSE OLD PISTON OR OLD BALANCE SPRING<BR>
5. Remove actuator screw by pressing on threaded end.<BR>
6. Remove shaft seal and thrust washer from actuator screw.<BR>
7. Remove old boot while being careful not to scratch the housing bore.<BR>
8. Remove piston seal, using a wood or plastic tool that will not damage the caliper bore.<BR>
9. Remove caliper mounting bolts, bushings and sleeves.<BR>
10. Remove bleeder screw.<BR>
<B>NOTICE:</B> If excessive resistance is encountered, use the following procedure to prevent breakage:<BR>
(A) First put a 10 mm socket over bleeder screw and tap lightly on it.<BR>
(B) If step (A) does not help, use a propane torch to heat the caliper around bleeder screw after assuring that any excess Liquid Wrench has been removed from surface. Apply heat to caliper for approximately 30 seconds to 1 minute (maximum). DO NOT USE AN ACETYLENE TORCH. Overheating the aluminum caliper could cause the bleeder screw to strip its threads.<BR>
11. Inspect caliper bore and seal groove. If necessary, use crocus cloth to polish out any light corrosion. <BR>
12. Clean all parts with GM brake parts cleaner P/N 12345754 (or equivalent). <BR>
13. Dry parts with unlubricated compressed air. <BR>
14. Blow out all passages in housing and bleeder screw. <BR>
15. Clean internal passage in bleeder screw, reinstall bleeder screw and torque to 6-9 N-m. (80-140 lb.in.). <BR>
16. Install new piston seal. Lubricate seal and bore with brake fluid. <BR>
<B>NOTICE:</B> Make sure that seal is not twisted.<BR>
17. Install lubricated new boot onto new piston with inside lip of boot in piston groove and boot fold toward end of piston which contacts inboard brake pad. <BR>
18. Install thrust washer on actuator screw with copper side of washer toward the piston assembly and gray surface toward the caliper housing. <BR>
19. Install lubricated shaft seal on actuator screw. <BR>
20. Install actuator screw into piston. <BR>
21. Install new balance spring into piston recess. <BR>
22. Guide lubricated piston assembly into lubricated bore of caliper.<BR>
<B>NOTICE:</B> Excessive force is not required to install the piston assembly into the caliper bore. <BR>
DO NOT ALLOW PISTON TO **** IN BORE AS SEAL WILL BE DAMAGED.<BR>
23. When resistance (seal engagement) is met, rotate piston assembly back and forth to insure it is square to seal.<BR>
24. Use # J-22269-01 to install piston through piston seal. Shake tool to align piston to the seal while gently turning the jack screw to push piston through the seal to the bottom of the caliper bore. See illustration below. <BR>
<IMG SRC="http://members.shaw.ca/crussel/insertion.gif"><BR>
25. Install lubricated antifriction washer and lever seal over end of actuator screw. <BR>
<B>NOTICE:</B> The sealing bead on the lever seal should be against the housing.
26. Install lever on actuator screw. Rotate lever away from stop slightly and hold while installing nut to 48 N-m (35 lb.ft.). Then, rotate lever back to contact stop. <BR>
27. Seat boot into caliper housing counter bore using new Kent-Moore tool # J-38898. <BR>
28. Install new dampening spring (included in kit) in groove on end of piston. <BR>
29. Clean, lubricate and reinstall sleeves, bushings and caliper mounting bolts.<BR>
30. Install brake shoes.<BR>
<P>
<B>H.</B> Reinstall calipers, per the appropriate shop manual.
<P>
<B>I.</B> Install hydraulic fitting and bolt, using 2 new brass washers, and torque to 33 N-m (24 lb.ft.).
<P>
<B>J.</B> Bleed brake system as required (power or manual), per shop manual.
<P>
<B>K.</B> Apply approximately 778N (175 lb.) force 3 times to the brake pedal to seat the linings.
<P>
<B>L.</B> Clinch outboard shoe to caliper, per shop manual.
<P>
<B>M.</B> Readjust park brake cable, per shop manual.
<P>
<B>N.</B> Reinstall wheels and tire assemblies.
<P>
<B>O.</B> Install Campaign Identification Label.
<P>
<B>Campaign Identification Label:</B><BR>
<P>
<img src="http://members.shaw.ca/crussel/label.gif">
<P>
Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label."
Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.
Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.
Apply "Campaign Identification Label" only on a clean, dry surface.
<HR>
<TABLE>
<TR><TH ALIGN=RIGHT>Number:<TD>86C28
<TR><TH ALIGN=RIGHT>Section:<TD>5
<TR>
<TR><TH ALIGN=RIGHT>Date:<TD>June, 1991
<TR>
<TR><TH ALIGN=RIGHT>Subject:<TD>PRODUCT SAFETY CAMPAIGN 86C28 REAR DISC BRAKE CONE CLUTCH PARK BRAKE ADJUSTER
<TR><TH ALIGN=RIGHT>Model and Year:<TD>1982-86 CHEVROLET CAMAROS WITH REAR DISC BRAKES (RPO J65) AND MANUAL TRANSMISSIONS
<TR>
<TR><TH ALIGN=RIGHT>To:<TD>All Chevrolet Dealers
</TABLE>
<P>
The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.
If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.
To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.
<P>
<B>Defect Involved</B><BR>
General Motors has determined that a defect which relates to motor vehicle safety exists in 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions. These vehicles may exhibit a lack of park brake automatic adjustment leading to reduced parking brake effectiveness.
To correct this condition, all involved vehicles will have an improved design rear brake caliper actuator installed. Other repairs to restore park brake functions to proper operation may also be made in conjunction with this campaign.
<P>
<B>Vehicles Involved</B><BR>
Involved are 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions, and built within the following VIN breakpoints:
<P>
<TABLE BORDER=1>
<TR><TH>YEAR<TH>MODEL<TH>PLANT<TH>CODE<TH>FROM<TH>THROUGH
<TR><TD ALIGN=CENTER>1982<TD ALIGN=CENTER>F-Car<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>CN100001<TD ALIGN=CENTER>CN168020
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>CL123326<TD ALIGN=CENTER>CL221394
<TR><TD ALIGN=CENTER>1983<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>DN103234<TD ALIGN=CENTER>DN165071
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>DL100280<TD ALIGN=CENTER>DL168650
<TR><TD ALIGN=CENTER>1984<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>EN100002<TD ALIGN=CENTER>EN200276
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>EL100004<TD ALIGN=CENTER>EL260754
<TR><TD ALIGN=CENTER>1985<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>FN100008<TD ALIGN=CENTER>FN176201
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>FL100079<TD ALIGN=CENTER>FL503417
<TR><TD ALIGN=CENTER>1986<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Norwood<TD ALIGN=CENTER>"N"<TD ALIGN=CENTER>GN100007<TD ALIGN=CENTER>GN188639
<TR><TD ALIGN=CENTER>"<TD ALIGN=CENTER>"<TD ALIGN=CENTER>Van Nuys<TD ALIGN=CENTER>"L"<TD ALIGN=CENTER>GL100002<TD ALIGN=CENTER>GL203370
</TABLE>
<P>
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
<P>
<B>Owner Notification & Dealer Responsibility</B><BR>
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter).
Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.
<P>
<B>Parts Information</B><BR>
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
<P>
<TABLE BORDER=1>
<TR VALIGN=TOP><TH>Part Number<TH> Description<TH> Quantity/Vehicle
<TR VALIGN=TOP><TD>18019028<TD> Rear Brake Caliper Actuator Kit<BR>
Each Kit Contains:
<UL>
<LI>2 Actuator Assemblies
<LI>All Necessary Gaskets & Seals
<LI>2 Brake Pad Dampening Springs
</UL><TD> 1
<TR VALIGN=TOP><TD>12300230<TD> Brake Pads<TD> As Required
<TR VALIGN=TOP><TD>18010361<TD> Actuator Levers<TD> As Required
<TR VALIGN=TOP><TD>10200446<TD> Parking Brake Cable<UL><LI>Front</UL><TD> As Required
<TR VALIGN=TOP><TD>10200448<TD> Parking Brake Cable Kit (Both Rear Cables)<UL>
<LI>P/N 10200443 Left Rear Cable
<LI>P/N 10200444 Right Rear Cable</UL><TD> As Required
<TR VALIGN=TOP><TD>10046472<TD> Parking Brake Apply Handle<TD> As Required
<TR VALIGN=TOP><TD>10139097<TD> Banjo Washer<TD> As Required
<TR VALIGN=TOP><TD>01052535<TD> Brake Fluid<TD> 1 Pint
</TABLE>
<P>
DEALERS ARE TO RETURN ALL SERVICE INVENTORY OF SEAL KIT P/N 18010453, ACTUATOR KIT P/N 18016369, AND REAR CALIPER P/N 18016374. PLEASE IDENTIFY THESE PARTS AS SPECIAL RETURNS ON YOUR PC659 DOCUMENT.
<P>
<B>Service Procedure</B><BR>
<B>A.</B> Raise vehicle and remove both rear tire/wheel assemblies.
<P>
<B>B.</B> Inspect park brake apply system for proper function, corrosion, kinks, etc. Remove nonfunctional cables.
<P>
<B>C.</B> Spray equalizer and both bleeder screws with Liquid Wrench (or equivalent product). Do not remove screws at this time.
<P>
<B>D.</B> Remove both rear calipers following the procedures in the appropriate Service Manual.
<P>
<B>E.</B> Remove brake pads.
<P>
<B>F.</B> Inspect brake pads for taper wear or excessive wear. Taper wear can be determined by taking measurements at the four points shown in the diagram below.
<P>
<IMG SRC="http://members.shaw.ca/crussel/brake_pad.gif">
<P>
Calculate pad taper by subtracting the thinnest point measured from the thickest point measured.
The brake pads should be replaced if taper is greater than .080 inches.
<P>
<B>G.</B> Overhaul calipers as follows:
<P>
Tools Required:
<TABLE BORDER=1>
<TR><TD>J-22269-01<TD>Piston Installer
<TR><TD>J-38898<TD>Boot Seal Installer
</TABLE>
<P>
1. Remove shoe damping spring from end of piston. <BR>
2. Remove park brake lever. <BR>
3. Remove lever seal and antifriction washer. <BR>
4. Remove piston by turning actuator screw with lever or wrench. <BR>
<B>NOTICE:</B> DO NOT REUSE OLD PISTON OR OLD BALANCE SPRING<BR>
5. Remove actuator screw by pressing on threaded end.<BR>
6. Remove shaft seal and thrust washer from actuator screw.<BR>
7. Remove old boot while being careful not to scratch the housing bore.<BR>
8. Remove piston seal, using a wood or plastic tool that will not damage the caliper bore.<BR>
9. Remove caliper mounting bolts, bushings and sleeves.<BR>
10. Remove bleeder screw.<BR>
<B>NOTICE:</B> If excessive resistance is encountered, use the following procedure to prevent breakage:<BR>
(A) First put a 10 mm socket over bleeder screw and tap lightly on it.<BR>
(B) If step (A) does not help, use a propane torch to heat the caliper around bleeder screw after assuring that any excess Liquid Wrench has been removed from surface. Apply heat to caliper for approximately 30 seconds to 1 minute (maximum). DO NOT USE AN ACETYLENE TORCH. Overheating the aluminum caliper could cause the bleeder screw to strip its threads.<BR>
11. Inspect caliper bore and seal groove. If necessary, use crocus cloth to polish out any light corrosion. <BR>
12. Clean all parts with GM brake parts cleaner P/N 12345754 (or equivalent). <BR>
13. Dry parts with unlubricated compressed air. <BR>
14. Blow out all passages in housing and bleeder screw. <BR>
15. Clean internal passage in bleeder screw, reinstall bleeder screw and torque to 6-9 N-m. (80-140 lb.in.). <BR>
16. Install new piston seal. Lubricate seal and bore with brake fluid. <BR>
<B>NOTICE:</B> Make sure that seal is not twisted.<BR>
17. Install lubricated new boot onto new piston with inside lip of boot in piston groove and boot fold toward end of piston which contacts inboard brake pad. <BR>
18. Install thrust washer on actuator screw with copper side of washer toward the piston assembly and gray surface toward the caliper housing. <BR>
19. Install lubricated shaft seal on actuator screw. <BR>
20. Install actuator screw into piston. <BR>
21. Install new balance spring into piston recess. <BR>
22. Guide lubricated piston assembly into lubricated bore of caliper.<BR>
<B>NOTICE:</B> Excessive force is not required to install the piston assembly into the caliper bore. <BR>
DO NOT ALLOW PISTON TO **** IN BORE AS SEAL WILL BE DAMAGED.<BR>
23. When resistance (seal engagement) is met, rotate piston assembly back and forth to insure it is square to seal.<BR>
24. Use # J-22269-01 to install piston through piston seal. Shake tool to align piston to the seal while gently turning the jack screw to push piston through the seal to the bottom of the caliper bore. See illustration below. <BR>
<IMG SRC="http://members.shaw.ca/crussel/insertion.gif"><BR>
25. Install lubricated antifriction washer and lever seal over end of actuator screw. <BR>
<B>NOTICE:</B> The sealing bead on the lever seal should be against the housing.
26. Install lever on actuator screw. Rotate lever away from stop slightly and hold while installing nut to 48 N-m (35 lb.ft.). Then, rotate lever back to contact stop. <BR>
27. Seat boot into caliper housing counter bore using new Kent-Moore tool # J-38898. <BR>
28. Install new dampening spring (included in kit) in groove on end of piston. <BR>
29. Clean, lubricate and reinstall sleeves, bushings and caliper mounting bolts.<BR>
30. Install brake shoes.<BR>
<P>
<B>H.</B> Reinstall calipers, per the appropriate shop manual.
<P>
<B>I.</B> Install hydraulic fitting and bolt, using 2 new brass washers, and torque to 33 N-m (24 lb.ft.).
<P>
<B>J.</B> Bleed brake system as required (power or manual), per shop manual.
<P>
<B>K.</B> Apply approximately 778N (175 lb.) force 3 times to the brake pedal to seat the linings.
<P>
<B>L.</B> Clinch outboard shoe to caliper, per shop manual.
<P>
<B>M.</B> Readjust park brake cable, per shop manual.
<P>
<B>N.</B> Reinstall wheels and tire assemblies.
<P>
<B>O.</B> Install Campaign Identification Label.
<P>
<B>Campaign Identification Label:</B><BR>
<P>
<img src="http://members.shaw.ca/crussel/label.gif">
<P>
Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label."
Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.
Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.
Apply "Campaign Identification Label" only on a clean, dry surface.
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