2. Check the thickness of the brake disc pads by looking through the groove in the caliper body. If the shim thickness on any of the pads is equal to or less than the minimum specified thickness, all four pads must be replaced.
Caliper Girling
3. Loosen the top and bottom guide pin bolts (photo).
4. Lift the caliper body, move it to the side (photo).
5. Remove the brake disc pads from the fastener hanger (photo). If the pads are to be reused, mark them so that they can be installed in their original positions.
6. Clean the caliper, piston, disc and pads from dust and dirt.
7. Rotate the disc by hand to remove rust and deposits. Carefully inspect the entire surface of the disc, if there are deep cracks or large wear, the disc must be replaced. Inspect the caliper around the piston. Replace piston seals or caliper body as needed.
8. If new pads are being installed, retract the piston into the hole by turning it clockwise while pushing (photo).
9. Place the pads in their position on the fastener hanger, install the caliper body onto the pads.
10. Install and tighten the new drive pin bolts to the torque specified in Specifications.
Caliper Teves
11. Remove the plastic covers from the guide bolts, unscrew the bolts just to free the caliper. Don't take them off completely.
12. Take the caliper body away from the car, turn it back, lift it off the blocks. Place the caliper on the side, do not bend the brake line pipe.
13. Get blocks from a suspension bracket of a fastener. If the pads are to be reused, mark them so that they can be installed in their original positions.
14. See steps 6, 7 and 8 before installing the pad. Note that on this caliper the piston retracts with a simple push.
15. Place the pads on the fastener hanger, then the caliper.
16. Fix the caliper with guide bolts, tightening them with the tightening torque specified in Specifications, install the plastic covers.
Girling and Teves calipers
17. Handbrake must be released.
18. Using a screwdriver, spread the hand brake control lever on the left caliper so that the lever rests on the limiter (Pic. 9.22 and 9.23). Lock the lever in this position, the control lever on the right caliper should be in the same position.
19. If the right lever is far from the stop after this procedure, loosen the handbrake cable set nut (Pic. 9.24) before installing both levers on the stops.
20. Insert a 6mm screwdriver between the governor control spring and the roller on the rear axle (Pic. 9.25).
21. With the engine off, pump the brake pedal about 40 times using moderate pressure, then check that both rear discs should rotate freely with the pedal released. If not, repeat the procedure given in steps 18-21, but loosen the handbrake cable adjusting nut further.
22. Finally, remove the screwdriver from the regulator, install the wheels, lower the car.
Pic. 9.18 View of Teves rear disc brake components (Chapters 10 and 11)
1 - Brake disc pads
2 - Setting springs
3 - Hanger fastener
4 - Brake disc
5 — Bolts of fastening of a suspension bracket of a fastener
6 - Caliper housing
7 - Guide bolt
8 - Bolt caps
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