'09 t/g installing p/m stage 1 rear brakes

May 8, 2011
757
14
peru,in,usa
the rear master cyl was easily removed. i just took off the brake pedal. got the brake lines run. now waiting for the new r/disc to come in on sat.

has anybody removed the rear axles? the p/m kit has new disc mounting ring, and the axle has to be removed to install it. as per manual the axle either come off easy or use a slide hammer.in my seeing things if you mark the axle relative to the housing then remove the axle the splines should line up when re-installing the axle. any other opinions appreciated.thanks no slideing hammer needed to remove axle. red thread locker on bolts. didn't have any trouble removeing them toqque 41-45* , but did have to use map gas to heat up 1 bolt. there is red threadlocker on the ft.

disc brake bolts, so heat them up before removeing then.

also buy (8) new 3/8x1 1/4, 24 thread bolts and grade 8 nuts ,

and you can get a 9/16" open-end wrench to tighten them up. the "T" bolts fit snug against the axle. and same only 1" for disc bolts. the axle are thru bolts (no threads in axle) OEM uses T bolts, so you can get a 14 MM socket on the nuts. grade 8 nuts work better when installing.. dealer has no nuts or bolts in stock, so preplan for this.also before you run the brake lines wrap the ends in k-mart bags & use a bread tie- to secure it. this will prevent any dirt fron getting into the lines. the i use 1/4x28 speedbleeders ( sb1428-ss 1/4x28)for the front and 3/8x24

sb3824-ss for the rears. Ss is stainless.

had 1 front. bleeder that wouldn't go in, so i wire brushed the threads, then ok.

tomorrow to install calipers, and bleed. i use DOT super blue 15.00 per ltr. and the next time amber colored brake fluid. available on line.when you route the brake lines hook upborh rear calipers but leave the nuts looose for alinement purposes later , then 2 rear lines to the line leading to the brake sensor. start from the very back and route the line to just over swing arm & to the rear of rt side cover. ft line install it to the brake resivor first then route the line along the lower frame. pull the line toward you and install the brake switch and tighten the line to the rear line. p/m master cylinder takes a 5/32 allen wrench
 
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I haven't had the axles out of mine yet, I am leaning towards installing the PM kit next winter. You'll have to let us know how much of a PIA it was to install.
 
my local shop guy just installed p/m stage 1 in his '09 t/g and had to use a slideing hammer to remove the axles. so thats what i'll do. he had some problems getting the clevis pin 's (cotter pin) out .bur i used a long skinny screwdriver after i jiggled the brake pedal to rotate the clevis pin so i could bend it straight and pulled it our with large pick i

bought as a set at auto zone.. didn't remove any exhaust. so i bent the old brake line quite a bit to get it out.aslowill have a friend use a pry bar as i use the hammer.on sat.

found the stage 1 on e bay for 800.00 as a open box but new. lucky as i want to lock all 3 wheels if needed.the parking brake is not used in p.m system so its gone.the clevis wouldn't fit (dry run) so i had to grind off some on the brake pedal ears so it would fit.junction block line is 12mm.haveing a hard time getting the rear calipers centered.need

.505", so i may have to grind down some washers to get the exact size, then try to buy them.the kit comes with shims but the chrome ones are too thick.
 
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