Cutlass L4-138 2.3L VIN A FI HP (1990)
Brake Caliper: Technical Service Bulletins
Brake Caliper, Rear - Service Procedure
NUMBER:
91-T-205
CORP.REF.NO: 135011
DATE:
October 1991
SECTION:
5
SUBJECT:
REAR BRAKE CALIPER SERVICE PROCEDURE
MODELS/YEARS:
1988-91 CUTLASS SUPREME
CONDITION: Some cases have been reported where it is difficult to remove the grooves when servicing the rear calipers on 1988-91 Cutlass
Supremes.
CAUSE:
This difficulty may be caused by NOT first removing the boot from the grooves in the ends of the sleeves. If not removed, the boot may
become wedged between the sleeve and the caliper bore.
CORRECTION:
To eliminate this difficulty, use the following procedure:
1.
Raise vehicle and remove rear wheels and tires.
2.
Remove hydraulic line bracket and bolt. (it is not necessary to disconnect hydraulic line from the caliper.)
3.
Remove park brake cable at actuator lever.
4.
Remove park brake cable, lever nut, lever, and spring.
5.
Remove caliper mounting bolts.
6.
Remove caliper and support on wire hanger.
7.
Remove brake pads.
8.
Remove both boots from grooves on sleeves and cut boots at caliper to remove exposed boots completely.
9.
Remove sleeves. The suggested method is use an air chisel with Kent-Moore Tool J-39495-1 to push each sleeve out.
10.
Clean housing bores and grooves, and bolt sleeves, with GM Brake Parts Cleaner, P/N 12345754 (or equivalent).
A Bores may be further cleaned with a 7/8" flex hone. Use Kent-Moore Tool J-39495-2 (or equivalent).
B.
Grooves may be cleaned with a wire brush. Use Kent-Moore Tool J-39495-3 (or equivalent).
Notice:
Grooves in caliper bores must have all contaminants removed before reassembling to insure proper fit of boot beads. Some minor pitting may
remain, this is acceptable.
11.
If sleeves cannot be cleaned, or are pitted, use new ones.
12.
Lubricate housing grooves, bore, I.D. and O.D. beads of new boots and sleeves.
Notice:
Use all of the grease from kit for one caliper (two sleeves), and insure all grooves are full of lube.
13.
Install lubricated boot into front groove in caliper bore.
14.
Make sure that boot is positioned into groove by pressing the bead into groove.
Notice:
If this is not done properly, the sleeve will push the boot out of the caliper when installation is attempted.
15.
Push lubricated sleeve in from rear of caliper through I.D. of installed boot until the rear end of sleeve is past the groove on rear of caliper.
16.
Install lubricated rear boot.
17.
Push sleeve back the other way through the 2nd boot, and seat the I.D. beads of both boots into grooves of sleeves. Repeat for other side.
18.
Clean caliper bridge (file and/or sand) where the inner pad guides. Lubricate this area with a thin film of HI-Temp grease.
19.
Retract caliper piston, per Service Manual.
20.
Reinstall brake pads.
21.
Reinstall caliper.
22.
Reinstall park brake lever, nuts and spring.
23.
Reinstall park brake cable at lever.
24.
Reinstall hydraulic line bracket and bolt.
25.
Check park brake cable adjustment.
