While I was rebuilding my rear calipers for '84 rear end I searched for some tips
but all found was a half-*** documentary where the guy left parts out in order
to get it together. I also noticed he didn't even clean it. This was not a source
for inspiration.

I decided to figure it out for my self. Now, I know this isn't the correct way
but it is certainly better than leaving parts out.

First I installed the spring washers (the top one is convex up/toward the head
of the screw and the rest alternate. Install the new o-ring and apply a thin coat
of assembly grease and drop in place.

Before installing the e-brake lever slide the reatining clip then the dust cover
over the shaft and turn inside-out.lube the bearings and install the return
spring then slide shaft in until it contacts the adjust screw.

I modified a c-clamp (you may not need to do this, I had attempted this another way and it kept slipping off so I mdified the clamp but then modified the procedure)on the stationary end to allow maximum srface area on the tiny edge of the screw (in the pics you can see that I just flattened one of the rounded edges) and found a socket that will allow the screw to slide through and long enough so that it stands just above the piston bore.

 

Placing the modified clamp end on the screw and the other on the socket, tighten the
clamp until you can slide the lever over the screw but before you do, apply some grease
in the groove of the screw and install that little wedge lookin' thingy.
With a plastic mallet tap on the end of the lever until you realize things
aren't lining up and you've almost contacted the opposite bearing.

 

Remove the clamp and modify the other end (the swiveling foot on the screw part
of the clamp). I used a die grinder to cut a large groove (roughly matching the
diameter of the shaft across the foot and polished it to a shine. Apply grease to
the groove and the shaft then place the grooved foot on the shaft and try to match
the angle you need to align the shaft with the bearing. Once they're alighned just
tap it home. Install clip, grease her up and and close the lid.

Now, install the PRE-soaked seal and screw the piston in.

 

never having done this before I have to say I have NO idea exactly what you are doing to what part of the caliper, but maybe for guys who have pulled these apart, this could be great! Nice photos! i'll have to leave the kudos for tech details up to others but appreciate the efforts to educate us!

I think - at least speaking for myself - we'd need a bit more detail of the whole process to get much value out of what you have tried to present.

Stu Aull
80GS
Alaska

 

I am aware of the vagueness but I kept putting of the post and finally sat down to type it out but the new meds I'm on make me anxious so I just screamed through it.

I do plan to edit soon.

Sorry for the confusion.

M

 

no worries - your time and effort appreciated by All!! Just would love a bit more detail to really get your hard work out to us brake-newbies!
look forward to any update or clarification you can add to this.
regards
Stu Aull
80GS
Alaska