900 L4-1985cc 2.0L SOHC (1988)
Fig. 3 Front brake caliper exploded view.
*** UPDATED BY TSB# 0786862 JULY 1986
A new front pad set combination is introduced into spare parts from 07/86. This new combination consists of two 2-pad combinations (P/N 91-02-708
Textar T474, 91-02-690 Delco 121) which require special installation considerations.
The alternative four pad organic set (P/N 89-93-297) remains as before and is still restricted for naturally aspirated cars that will never be used in
severe service (e.g., sustained city driving mountainous driving). The service life of this set is less than that of the new semi-metallic front combination.
1.
Raise vehicle and remove wheel.
2.
Rotate disc so recess in disc aligns with pads.
3.
Remove damper spring, pin retaining clip, and U-pin on Girling type caliper, Fig. 1, or retaining pins, and spring on ATE type caliper, Fig. 2. On
9000 models, remove lower guide pin bolt and pivot caliper upward, Fig. 3.
4.
Remove pads either by hand or with extractor No. 8995771.
5.
Remove rust and worn edges from the brake disc. Check the condition of the dust covers on the piston. Replace of cracked or damaged. If the
brake fluid is suspect, is should be changed. Check the vehicles service records or interview the customer. Brake fluid should be changed every 2
years or 30,000 miles. Use DOT 4 (never use DOT 5).
6.
Check that the hand brake actuating lever at the caliper moves freely. Clean and grease the sliding surface of the brake housing for the yoke and
pads. Use Gleitmo 540 (P/N 30-08-612).
7.
Check the hand brake cable clearance 0.019 ± .003" (0.5 ± 0.1 mm) at the caliper levers and adjust if necessary.
8.
Turn in the pistons with the aid of the special tool (P/N 89-96-043). Do not turn in the pistons past the point where they are in line with the plane
of the hole for the pad retaining pin.
9.
Semi-Metallic 2-Pad Combination:
Place Textar T474 pad (P/N 91-02-708) on the inside of the disc. Place Delco 12 pad (P/N 91-02-690) on the outside of the disc. Inner pads (Textar
T474) may wear at a faster rate than outer pads (Delco 121) and may be replaced in sets of two. It's not necessary to replace all four pads if only the
inners are worn. (Outer pads must have at least 4 mm of pad material remaining).
Organic Moderate-Use Pads:
Place pads from the four pad (89-93-297) set on both sides of the disc.
10.
Pull up the hand brake 7 notches. Start the engine and pump the brake pedal until the hand brake lever will operate after 9-10 notches. Pulling up
on the hand brake lever blocks the self-adjusting mechanism of the brake pistons and prevents over adjustment.
11.
Road test the car to verify correct brake function but do not overheat the pads with repeated hard braking. Do not apply high static force at the
pedal. This can cause piston over adjustment. Advise the owner to bed-in the pads gently, e.g. avoid hard braking for the first 90 miles (city
driving) or 300 miles (highway driving).
