boot CHEVROLET DYNASTY 1993 Owner's Manual

(2) Install boot onto interconnecting shaft, position
boot on the flat between the locating shoulders (Fig. 16).
(3) Position clamp on boot and crimp bridge of
clamp with Crimper Special Tool C-4124.
(4) Install the C/V Joint following the procedure
outlined under Inner C/V Joint Assemble .
(5) Position the large end of boot on housing and
install clamp, crimp bridge of clamp with Crimper,
Special Tool C-4124.
CAUTION: During any service procedures where
knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve with suitable solvent
and lubricate BOTH components at assembly. Do
not allow solvent to contact boot.
Lubricate wear sleeve (and seal) with Mopar Multi-
Purpose Lubricant, or equivalent, as follows: Wear Sleeve: Apply a full circumference 6 mm
(1/4 inch) bead of lubricant to seal contact area. See
(Fig. 11), Driveshaft Assemblies Install. Seal: Fill lip to housing cavity (full circumference)
and wet seal lip with lubricant.
S.S.G INNER C/V JOINT LARGE CLAMP (MANUAL TRANS ONLY)
(1) Install small clamp and inner C/V joint housing
according to the procedures outlined in this manual. (2) Position the boot over the outer C/V joint.
(3) Slide the large band clamp over the boot and
position it evenly in the groove on the inner C/V
joint boot. (Fig. 17). (4) Use Clamp Locking Tool Snap-On YA3050 or
equivalent shown in (Fig. 18) to install the clamp on
the boot. (5) Place the prongs of the clamp locking tool in
the holes on the clamp and squeeze together until
the two ends meet (Fig. 18).
DAMPER WEIGHTS
Damper weights are used on the left driveshaft as-
semblies of all front wheel drive vehicles (Fig. 19).
These weights are attached to the interconnecting
shaft and are available as a separate service part. They should be removed from the driveshaft assem-
bly during driveshaft positioning specification proce-
dures. When the weights are attached between the
locating shoulders, tighten the fasteners to the fol-
lowing specifications:
² S.S.G. Ð 28 N Im (21 ft. lbs.)
² G.K.N. Ð 30 N Im (23 ft. lbs.)DRIVESHAFT POSITIONING SPECIFICATIONS
Front wheel drive vehicles have engine mounts with
slotted holes allowing for side to side positioning of the
engine. If the vertical bolts on right or left upper engine
Fig. 16 Right Inner C/V Joint S.S.G.
Fig. 17 Boot Clamp Installed
Fig. 18 Locking Boot Clamp
2 - 48 SUSPENSION AND DRIVESHAFTS Ä

mount have been loosened for any reason, or if vehicle
has experienced front structural damage, driveshaft
lengths must be checked and corrected, if required. A
shorter than required driveshaft length can result in ob-
jectionable noise. A longer than required driveshaft
length may result in potential damage.
Use of the following procedure will ensure satisfac-
tory driveshaft engagement under all normal vehicle
operating conditions. (1) The vehicle must be completely assembled.
Front wheels must be properly aligned and in the
straight ahead position. The vehicle must be in a po-
sition so that the full weight of the body is distrib-
uted to all four tires. A platform hoist, or front end
alignment rack, is recommended.
(2) Using a tape measure or other suitable measuring
device. Measure the direct distance from the inner edge of the outboard boot to the inner edge of the inboard
boot on both driveshafts. This measurement must be
taken at the bottom (six o'clock position) of the drive-
shafts (Fig. 1).
Note that the required dimension varies with car-line,
engine, transaxle, and driveshaft manufacturer (Fig. 2).
(3) If the lengths of both shafts are within the
range specified, no further action is required. If either left or right driveshaft length is not
within the specified range. Refer to Group 09, Engine
Removal and Installation to properly position engine
according to specified driveshaft lengths.
(4) If proper driveshaft lengths cannot be achieved
within the travel limits available in the slotted engine
mounts. Check for any condition that could effect the
side to side position of the measurement locations (e.g.,
engine support brackets, siderail alignment, etc.).
(5) After ensuring proper driveshaft lengths the
transmission shift linkage must be adjusted to en-
sure proper operation. Refer to Transaxle, Group 21.
Fig. 2 Driveshaft Identification and Dimensions
Fig. 19 Left Driveshaft with Damper Weight
Fig. 1 Driveshaft Positioning
Ä SUSPENSION AND DRIVESHAFTS 2 - 49

BRAKES
CONTENTS
page page
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 10 AC/Y BODY ............. 72
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 6 AA,AG,AJ,AP BODY ....... 113
BRAKE DISC (ROTOR) ................... 53
BRAKE SUPPORT ASSEMBLY ............. 25
FRONT DISC BRAKES ................... 31
GENERAL INFORMATION .................. 1
HYDRAULIC SYSTEM CONTROL VALVES . . . 26
KELSEY HAYES DOUBLE PIN FAMILY CALIPER ............................ 35 KELSEY HAYES DOUBLE PIN NON-FAMILY
CALIPER ............................ 38
MASTER CYLINDER ..................... 66
PARKING BRAKES ...................... 57
POWER BRAKES ....................... 68
REAR DISC BRAKES .................... 45
REAR WHEEL DRUM BRAKES ............ 18
SERVICE ADJUSTMENTS .................. 4
WHEEL BEARINGS ...................... 70
WHEEL CYLINDERS ..................... 23
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the break down of these designa-
tions is included in the Introduction Section at the
front of this service manual. Standard brake equipment consists of:
² Double pin floating caliper disc front brakes.
² Rear automatic adjusting drum brakes.
² Differential valve with a brake warning switch.
² Master cylinder.
² Vacuum power booster.
² Double pin floating caliper rear disc brakes are
available on some models. The Bendix Anti-Lock 10 braking system, uses the
standard power brake system caliper assemblies,
braking discs, pedal assembly, brake lines and hoses.
The unique parts of the Bendix Anti-Lock 10 braking
system consists of the following components. Propor-
tioning valves, wheel speed sensors, tone wheels,
electronic control unit, modulator assembly and hy-
draulic assembly. These components replace the con-
ventional master cylinder and power booster. The
components will be described in detail in the Bendix
Anti-Lock 10 brake section in this group of the ser-
vice manual. The Bendix Anti-Lock 6 braking system, uses the
following standard brake system components. Master
cylinder, power booster, caliper assemblies, braking
discs, pedal assembly, brake lines and hoses. The
unique parts of the Bendix Anti-Lock 6 braking sys-
tem consists of the following components. Modulator
assembly, unique proportioning valves, wheel speed
sensors, tone wheels, and electronic control unit.
These components will be described in detail in the
Bendix Anti-Lock 6 brake section in this group of the
service manual. The front disc brake shoes have semi-metallic lin-
ings. The hydraulic brake system (Fig .123and4)is
diagonally split on both the Non-ABS and ABS brak-
ing system. With the left front and right rear brakes
on one hydraulic system and the right front and left
rear on the other. The Non-ABS and ABS brake system may use dif-
ferent types of brake line fittings and tubing flares.
The Non-ABS brake system uses double wall tubing
flares and fittings at all tubing joint locations. Some
ABS brake systems use both ISO style tubing flares
and double wall tubing flares and corresponding fit-
tings at different joint locations. See (Figs . 2 3 and 4)
for specific joint locations and type of tubing flare. The front disc brakes consist of two different types
of caliper assemblies. A double pin Kelsey-Hayes cal-
iper (family caliper) with a bolt-on adapter attached
to the steering knuckle. Or a double pin Kelsey-
Hayes caliper (non-family caliper) which mounts di-
rectly to rails on the steering knuckle. The non-
family caliper is only used on the AY Body
(Imperials).
CAUTION: Caliper pistons, boots and seals for the
different caliper assemblies used on the front and
rear disc brake assemblies are not interchangeable.
Misusage could result in a complete brake system
failure. Be sure that the parts are replaced with the
correct replacement parts, refer to the parts book
for the type and model year of the vehicle being
worked on.
The master cylinder is anodized, lightweight alu-
minum, with a bore size of 24.0mm, 21.0mm or 7/8
inch.
Ä BRAKES 5 - 1

Install grease cap and wheel and tire assemblies.
Tighten wheel stud nuts to 115 N Im (85 ft. lbs.)
torque on all models. Install wheel covers.
BRAKE SHOE ASSEMBLIES
Three brake shoe assemblies are used on the front
wheel drive passenger cars. Vehicles will have axle
sets of either 200 or 220 mm Kelsey Hayes (Fig. 2),
or Varga (Fig. 3). Varga brake shoes are HANDED
for right or left side. Except for brake shoe to support plate, park brake
lever retention and automatic adjuster positioning
guide buttons, service procedures for either assembly
are essentially the same.REMOVAL
Remove automatic adjuster spring and lever (Fig.
4).
Rotate the automatic adjuster screw assembly so
that each shoe assembly moves out far enough to be
free from the wheel cylinder boots (Fig. 5).
Disconnect the parking brake cable from the park-
ing brake lever (Fig. 6).
Fig. 2 Kelsey Hayes 200 And 220 (Left) Rear Wheel Brake
Fig. 3 Varga (Left) Rear Wheel Brake
Fig. 4 Remove or Install Adjuster Lever Spring
Fig. 5 Expand or Retract Adjuster Screw
Ä BRAKES 5 - 19

If old springs have overheated or are damaged, re-
place. Overheating indications are paint discoloration
or distorted end coils. Varga brake springs are not
painted but overheating of the brake springs will be
noted by any Blueing of the springs.
BRAKE SHOE INSTALLATION
Lubricate the eight shoe contact areas on the sup-
port plate and anchor using Mopar Multi-Purpose
Lubricant or equivalent (Fig. 11).
KELSEY HAYES REASSEMBLE
Assemble the park brake lever and wave washer to
the new replacement shoe (Fig. 9). Attach upper return spring between the two new
shoe assemblies. Apply a small amount of Mopar Multi-Purpose Lu-
bricant or equivalent to the automatic adjuster screw
assembly. Install adjuster with the two stepped forks
facing toward the outboard side of the shoes (Fig.
10). The longer fork will be pointing to the rear. Connect the lower shoe to shoe spring. Expand the automatic adjuster so that the end of the
shoes will clear the wheel cylinder boots. Position the
brake shoe assemblies on support plate and install
holddown springs (Fig. 7). Install self adjuster lever and spring.
Connect park brake cable.
Adjust brake shoes so that they will not interfere
with the drum installation.
CAUTION: Make sure the adjuster screw nut contacts
the adjuster tubular strut.
Install the drums and pump the brake pedal
several times to partially complete the shoe ad-
justment. After adjusting the Parking brake cable (see Adjust-
ing Parking Brake), road test vehicle. The automatic
adjuster will continue the brake adjustment during the
test.
VARGA REASSEMBLE
(1) Install park brake cable in park brake lever of
trailing shoe. (2) Attach trailing shoe, then leading shoe lower
springs to shoes and anchor plate. (3) Position shoes on support plate and install hold-
down springs. (4) Install automatic adjusters. Left side adjuster
has left hand threads and right side adjuster has
right-hand threads. Do not interchange sides.
Make sure adjuster is installed correctly. (Adjuster
ends must be above extruded pins in web of shoe as
shown in Fig. 3). (5) Install upper shoe to shoe spring. Ensure that
the spring terminal ends are fully engaged in the shoe
webs. (6) Rotate serrated adjuster nut to remove free play
from the adjuster assembly. (7) Install the adjuster lever on the leading shoe
pivot pin. Then attach the short end of the adjuster
spring into the hole on the lever. Then install the long
end of the spring in the leading shoe hole. (8) Connect park brake cable and adjust brake shoes
so as not to interfere with drum installation.
BRAKE DRUM REFACING
Measure drum runout and diameter. If not to speci-
fication, reface drum. (Runout should not exceed
0.1524 mm or 0.006 inch). The diameter variation (oval
shape) of the drum braking surface must not exceed
either 0.0635 mm (0.0025 inch) in 30É or 0.0889 mm
(0.0035 inch) in 360É. All drums will show markings of maximum allowable
diameter (Fig. 12).
Fig. 10 Adjuster Screw and Lever (Typical)
Fig. 11 Shoe Contact Areas on Support Plate
Ä BRAKES 5 - 21

WHEEL CYLINDERS INDEX
page page
General Information ....................... 23
Installing Wheel Cylinders .................. 24 Service Procedures
....................... 23
GENERAL INFORMATION
The piston boots are of the push-on type and pre-
vent moisture from entering the wheel cylinder. To perform service operations or inspections of the
rear wheel brake cylinders. It will be necessary to re-
move the cylinders from the support plate and disas-
semble on the bench.
CAUTION: Wheel cylinders with cup expanders
must have cup expanders after any service proce-
dures (reconditioning or replacement).
SERVICE PROCEDURES
REMOVING WHEEL CYLINDERS FROM BRAKE SUPPORT PLATES
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Then
block the brake pedal in the stroke position, and vi-
sually check the boots for cuts, tears, or heat cracks.
If any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed. (A slight amount of fluid on the boot
may not be a leak, but may be preservative fluid
used at assembly.) (1) In case of a leak, remove brake shoes, (replace
if soaked with grease or brake fluid.) (2) Thoroughly clean area of wheel cylinder, where
hydraulic brake line connects to wheel cylinder. Dis-
connect hydraulic brake tube from wheel cylinder
(Fig. 1). (3) Remove the rear wheel cylinder attaching bolts
(Fig. 1). Then pull wheel cylinder assembly off the
brake support plate (Fig. 2). (4) Clean the surface sealant off the support plate
and wheel cylinder surfaces.
DISASSEMBLING WHEEL CYLINDERS
To disassemble the wheel cylinders, (Fig. 3) pro-
ceed as follows: (1) Pry boots away from cylinders and remove.
(2) Press INon one piston to force out opposite pis-
ton, cup and spring (with cup expanders). Then using
a soft tool such as a dowel rod, press out the cup and
piston that remain in the wheel cylinder. (3) Wash wheel cylinder, pistons, and spring in
clean brake fluid or alcohol; (DO NOT USE ANY
PETROLEUM BASE SOLVENTS) clean thor- oughly and blow dry with compressed air. Inspect
Fig. 1 Brake Tube Disconnected
Fig. 2 Remove or Install Wheel Cylinder
Ä
BRAKES 5 - 23

cylinder bore and piston for scoring and pitting. (Do
not use a rag as lint from the rag will stick to bore
surfaces.) Wheel cylinder bores and pistons that are scored or
pitted in any way should be replaced. Cylinder walls
that have light scratches, or show signs of corrosion,
can usually be cleaned with crocus cloth, using a cir-
cular motion. Black stains on the cylinder walls are
caused by piston cups and will not impair operation
of cylinder.
ASSEMBLING WHEEL CYLINDERS
Before assembling the pistons and new cups in the
wheel cylinders, dip them in clean brake fluid. If the
boots are deteriorated, cracked or do not fit tightly
on the pistons or the cylinder casting, install new
boots. (1) Coat cylinder bore with clean brake fluid.
(2) Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with
open end of cups facing each other (Fig. 3). (3) Install piston in each end of cylinder having
the flat face of each piston contacting the flat face of
each cup, already installed (Fig. 3). (4) Install a boot over each end of cylinder. Be
careful not to damage boot during installation.
INSTALLING WHEEL CYLINDERS
(1) Apply Mopar tGasket In-A-Tube or equivalent
sealant around wheel cylinder mounting surface (Fig.
4). (2) Install wheel cylinder onto brake support, and
tighten the wheel cylinder to brake support plate at-
taching bolts to 8 N Im (75 in. lbs.). (3) Attach hydraulic brake tube to wheel cylinder,
and tighten tube to wheel cylinder fitting to 17 N Im
(145 in. lbs.). (4) Install brake shoes on support plate.
(5) Install rear brake drum onto rear hub. Install
rear wheel and tire assembly, tighten wheel stud
nuts to 115 N Im (85 ft. lbs.).
(6) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual. (7) Bleed the entire brake system. See (Bleeding
Brake System) in Service Adjustments section in this
group of the service manual.
Fig. 3 Rear Wheel Cylinder
Fig. 4 Apply Sealant on Support Plate
5 - 24 BRAKES Ä

A square cut rubber piston seal is located in a ma-
chined groove in the cylinder bore. This provides a
hydraulic seal between the piston and the cylinder
wall (Fig. 6). A molded rubber dust boot is installed in a groove
of the caliper assembly piston bore. This prevents
contamination in the bore area of the caliper assem-
bly. The boot mounts in the cylinder bore opening and
in a groove in the piston (Fig. 6). This prevents con-
tamination in the bore area. As lining wears, master cylinder reservoir brake
fluid level will go down. If brake fluid has been
added to the reservoir, reservoir overflow may occur
when the piston is pushed back into the new lining
position. Overflowing can be avoided in this case by
removing a small amount of fluid from the master
cylinder reservoir. All Vehicles, are equipped with an audible wear
sensor on the outboard pad of the front disc brake as-
Fig. 2 Front Disc Brake Assembly (Non-Family Caliper Typical)
Fig. 3 Disc Brake Caliper Mounting (Family Caliper)
5 - 32 BRAKES Ä

CLEANING AND INSPECTION
Check for piston seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
or fluid leak is visible, disassemble caliper assembly
and install a new seal and boot,(and piston if scored).
Refer to procedures titled Disc Brake Caliper Disas-
sembly. Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition. Re-
place if they are damaged, dry, or found to be brittle.
Refer to Cleaning And Inspection Of Brake Caliper.
BRAKE SHOES INSTALL
(1) Thoroughly clean and lubricate both adapter
ways on the steering knuckle, with a liberal amount
of Mopar Multi-purpose Lubricant, or equivalent. (2) The inboard brake shoes are common. The out-
board brake shoes are marked with an (LH) or (RH)
to denote which side of the vehicle to be installed on
(Fig. 6).
(3) Remove protective paper from the noise sup-
pression gasket and position the properly marked
outboard brake shoe assembly onto the caliper (Fig.
7). (4) Install new inboard brake shoe assembly in cal-
Fig. 3 Storing Caliper
Fig. 4 Prying Outboard Shoe Assembly Away from Caliper
Fig. 5 Removing or Installing Inboard ShoeAssembly
Fig. 6 Brake Shoe Identification
Ä BRAKES 5 - 39

iper, by installing retaining clip into the bore of the
piston (Fig. 5).
CAUTION: Use care when installing the caliper as-
sembly onto the steering knuckle, so the seal on the
sealed for life bushings does not get damaged.
(5) Carefully lower caliper over braking disc and
guide holddown spring under machined abutment on
knuckle assembly (Fig. 8).
(6) Install caliper guide pin bolts and tighten to
24-34 N Im (18-25 ft. lbs.) torque. When installing guide pin bolts, use extreme caution not to cross
thread the guide pin bolts.
(7) Install wheel and tire assembly. Tighten stud
nuts in proper sequence until all nuts are torqued to
half specification. This is important. Then repeat
sequence to full specification. (8) Remove jackstands or lower hoist. Before mov-
ing vehicle be sure it has a firm pedal, pump
pedal several times. (9) Road test vehicle and make several stops to
wear off any foreign material on the brakes and
to seat the linings.
DISC BRAKE CALIPER DISASSEMBLY
CLEANING AND INSPECTION
Check for piston fluid seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of piston dust boot. If boot is damaged, or fluid
leak is visible, disassemble caliper assembly and in-
stall a new seal and boot,(and piston if scored). Refer to
procedures titled Disc Brake Caliper Disassembly. Check the caliper dust boot and caliper pin bushings
to determine if they are in good condition. Replace if
they are damaged, dry, or found to be brittle. Refer to
Cleaning And Inspection Of Brake Caliper. (1) Remove caliper from braking disc (See Brake
Shoe Removal). Hang assembly on a wire hook away
from braking disc, so hydraulic fluid cannot get on
braking disc (See Fig. 3 in Brake Shoe Removal). Place
a small piece of wood between the piston and caliper
fingers. (2) Carefully depress brake pedal to hydraulically
push piston out of bore. (Brake pedal will fall away
when piston has passed bore opening.) Then prop up
the brake pedal to any position below the first inch of
pedal travel, this will prevent loss of brake fluid from
the master cylinder. (3) If both front caliper pistons are to be removed,
disconnect flexible brake line at frame bracket after
removing piston. Plug brake tube and remove piston
from opposite caliper. Using the same process as above
for the first piston removal.
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE BE USED TO REMOVE PISTON FROM
CALIPER BORE. PERSONAL INJURY COULD RE-
SULT FROM SUCH A PRACTICE.
(4) Disconnect brake flexible hose from the caliper.
To disassemble, mount caliper assembly in a vise
equipped with protective jaws.
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
Fig. 7 Installing Outboard Shoe Assembly onto Cali- per
Fig. 8 Guiding Holddown Spring Under MachinedAbutment
5 - 40 BRAKES Ä