Front Brake Assembly

Fig. 1 Delco-Moraine series 5349 front disc brake caliper exploded view:

Fig. 3 Compressing front caliper piston for caliper removal:

CALIPER REMOVAL
1. Drain approximately 2/3 of brake fluid from master cylinder assembly.
2. Raise and support vehicle, then remove tire and wheel assembly.
3. If caliper is to be serviced or replaced, remove bolt securing inlet fitting, then disconnect brake hose and secure in raised position. If only shoe and lining assemblies are being replaced, do not disconnect brake hose from caliper.
4. Remove caliper retaining bolts and boots, Fig. 1.
5. Compress piston, placing suitable adjustable pliers over inboard surface of caliper housing and support bracket as shown in Fig. 3.
6. Remove caliper from disc. If shoe and lining assemblies are to be replaced, use a length of wire to suspend caliper. Do not allow caliper to hang from brake line.




SHOE & LINING REMOVAL
1. Remove caliper as described under ``Caliper Removal.''
2. To remove outboard shoe and lining assembly, use a suitable screwdriver to disengage shoe buttons from caliper holes.
3. Remove inboard shoe and lining assembly from caliper.
4. Remove sleeves from mounting bolt holes.
5. Remove bushings from mounting bolt hole grooves.

CALIPER DISASSEMBLY
1. Position a clean shop towel on inside of caliper, then using compressed air, remove piston from caliper.
2. Remove piston protector from piston.
3. Inspect piston for wear, corrosion or damage. Replace piston, if necessary.
4. Inspect caliper housing for corrosion. If corrosion exists, use a crocus cloth to remove light surface corrosion. If corrosion cannot be removed with crocus cloth, replace caliper.
5. Remove bleeder valve protector.

CALIPER ASSEMBLY
1. Clean all brake components in clean denatured alcohol. Use dry, filtered compressed air to dry components and blow out caliper housing passages.
2. Install bleeder valve onto caliper. Torque valve to 80---140 inch lbs.
3. Using clean brake fluid, lubricate caliper housing bore and bore seals.
4. Install piston seal into caliper bore groove. Ensure seal is not twisted in groove.
5. Install boot and piston protector onto piston.
6. Install piston into caliper bore and push piston completely to the bottom.
7. Using tool No. J-29077 or equivalent, install boot into caliper housing counterbore.

SHOE & LINING INSTALLATION
1. Lubricate, then install bushings into mounting bolt hole grooves.
2. Lubricate, then install sleeves into mounting bolt holes.
3. Install inboard shoe and lining onto caliper. Ensure that tabs on inboard shoe are positioned so that they fit into corresponding holes in face of piston.
4. Install outboard shoe and lining onto caliper. Ensure wear sensor is positioned at leading edge of brake shoe.

CALIPER INSTALLATION
1. Install caliper onto brake rotor mounting bracket.
2. Using silicone grease or equivalent, liberally coat shoulder and mounting bolt threads so caliper cavity will be filled.
3. Install caliper mounting bolts. Torque bolts to 21---35 ft. lbs.