300M, Concorde, Intrepid, LHS, 1998-2004

Brake Caliper


Removal & Installation

Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions section.
  3. Remove or disconnect the following:

    Wheel and tire assemblies
    2 caliper guide pin bolts and remove the caliper assembly. If the caliper is not being removed from the vehicle as during brake pad renewal, simply hang the caliper with a piece of wire to take the weight off the brake hose.
    Bolt retaining the brake hose to the caliper. Be sure to plug the end of the brake hose or cover it with a plastic bag to prevent contamination from entering the hydraulic system.
    Caliper from the vehicle

    Click image to see an enlarged view

    Fig. Removal and installation of the brake caliper



To install:

  1. Install or connect the following:

    Brake hose to the caliper, if removed, using new sealing washers

  3. If new linings are being installed, the caliper pistons must be pushed back into their bore to accommodate the thickness of the new lining. Special tools are available for this, although a large C-clamp can often be used. It is good practice to remove some brake fluid from the master cylinder reservoir. This prevents overflow caused by brake fluid being forced through the lines as the piston is pushed back.

    Brake pads into the caliper
    Brake caliper to the caliper adapter. Lightly lubricate machined areas that support the caliper with high-temperature grease.
    Caliper guide pin bolts. Use care not to cross the threads of the caliper pin bolts. Torque the guide pin bolts to 17 ft. lbs. (22 Nm).
    Brake hose fittings to 35 ft. lbs. (48 Nm)

  5. Be sure to bleed the brake system.

    Wheels and lug nuts. Torque the wheel lug nuts in a star pattern sequence to 100 ft. lbs. (135 Nm).

  7. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal.
  9. Check the level of the brake fluid and add DOT 3 brake fluid, if necessary.
  11. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake linings, if replaced.