Avenger 2008

Brake Calipers

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Removal & Installation



  1. Using a brake pedal holding tool, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened.

    Click image to see an enlarged view

    Fig. Use a brake pedal holding tool

  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the wheel mounting nuts, then the tire and wheel assembly.
  6.  
  7. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are two washers (3) that will come off with the banjo bolt. Discard the washers.
    NOTE
    When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed.



    Click image to see an enlarged view

    Fig. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5)

  8.  
  9. Remove the two brake caliper guide pin bolts (2, 3).

    Click image to see an enlarged view

    Fig. Remove the two brake caliper guide pin bolts (2, 3)

  10.  
  11. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove.
  12.  

To install:

  1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
    CAUTION
    Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots.

  2.  
  3. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket.
    NOTE
    When installing the caliper guide pin bolts make sure that the one that has a special sleeve on the end is installed in the upper mounting hole.

  4.  
  5. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) and lower caliper guide pin bolts. Tighten the guide pin bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the banjo bolt connecting the brake flex hose to the brake caliper. Install NEW washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 18 ft. lbs. (24 Nm).
  8.  
  9. Install the tire and wheel assembly.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the brake pedal holding tool.
  14.  
  15. Bleed the caliper as necessary.
  16.  
  17. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
  18.  

 
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