Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Brake Caliper

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Removal & Installation



Not for Dodge Stratus Sedan

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    About half of the brake fluid from the master cylinder
     
    Wheel assembly
     

  4.  
  5. Position a C-clamp or other suitable tool over the caliper. Smoothly apply pressure, forcing the caliper piston into the caliper bore until it bottoms. Remove the compressor.

    Brake hose attaching bolt and hose from the caliper, if the caliper is to be completely removed from the vehicle. Plug the hose to prevent fluid contamination or loss.
     
    Caliper mounting bolts and lift the caliper off of the support bracket
     
    Caliper from the vehicle. If the caliper is only removed for access to other components, support the caliper with the brake hose attached so that there is no strain on the brake hose.

    Click image to see an enlarged view

    Fig. Exploded view of the front disc brake assembly



    Click image to see an enlarged view

    Fig. Brake caliper with slide and lock pin fasteners-2.4L



    Click image to see an enlarged view

    Fig. Brake caliper bolted to slide and lock pins-3.0L

     

  6.  

To install:

  1. Install or connect the following:

    Caliper support bracket, if removed, and torque the bolts to 74 ft. lbs. (100 Nm).
     
    Caliper to the support bracket. Install the mounting bolts. Torque the bolts to 28 ft. lbs. (100 Nm).
     
    Brake line hose to the caliper with new gaskets, if removed, and torque the inlet fitting bolt to 22 ft. lbs. (29 Nm)
     
    Master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system.
     
    Wheel assembly
     

  2.  
  3. Depress the brake pedal 3-4 times to seat the brake linings and to restore pressure in the system.
    CAUTION
    Do not move the vehicle until a firm pedal is obtained.

  4.  

  1. Remove the front wheels.
  2.  
  3. Remove the 2 caliper-to-steering knuckle guide pin bolts.
  4.  
  5. If the caliper is to be removed from the vehicle completely, for example, for overhaul perform the following procedure.
    1. Disconnect the brake hose from the caliper.
    2.  
    3. Cover the opening of the brake hose so the hydraulic system does not become contaminated.
    4.  

  6.  
  7. Remove the caliper from the steering knuckle.
  8.  

To install:

  1. Clean and lubricate both steering knuckle abutments with a coating of multipurpose grease.
  2.  
  3. Position the caliper and brake pad assembly over the brake rotor. Be sure to properly Install the caliper assembly into the abutments of the steering knuckle. Be sure the caliper guide pin bolts, rubber bushings and sleeves are clear of the steering knuckle bosses.
  4.  
  5. Reinstall the caliper guide pin bolts and torque to 16 ft. lbs. (22 Nm). On Sebring, torque the caliper guide pin bolts to 54 ft. lbs. (74 Nm).
  6.  
  7. If removed, connect the brake hose to the caliper and torque to 35 ft. lbs. (48 Nm).
  8.  
  9. Properly bleed the brake system.
  10.  
  11. Reinstall the wheel and tire and torque the lug nuts in a star pattern sequence to half specification. Repeat the tightening procedure to full specified torque of 95-100 ft. lbs. (129-135 Nm).
  12.  
  13. Pump the brake pedal to seat the front brake pads before moving the vehicle.
  14.  
  15. Check and adjust brake fluid level as necessary.
  16.  
  17. Road test vehicle to check for proper brake operation.
  18.  

  1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove the front wheel and tire assembly.
  6.  
  7. Remove the anti-rattle spring from the outboard side of the caliper and adapter.
  8.  
  9. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers.
  10.  
  11. Remove the two caps in place over the caliper guide pin bolts.
  12.  
  13. Remove the two caliper guide pin bolts.
  14.  
  15. Remove the caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed.

    Click image to see an enlarged view

    Fig. Front caliper mounting-2005 models shown

  16.  

To install:

  1. Completely retract the caliper piston back into piston bore of the caliper.
  2.  
  3. Lubricate both caliper adapter abutments where the shoes slide with a sufficient amount of MOPAR® Silicone Grease, or equivalent.
    NOTE
    If pads are being transferred or newly installed, make note that the inboard brake pads are stamped L or R for left or right side of the vehicle. The P-slot or void on piston insulator must be positioned upward when brake caliper is mounted.


    WARNING
    Use care when installing the brake caliper assembly onto the adapter, so that the seals on the caliper guide pin bushings do not get damaged by the adapter bosses.

  4.  
  5. Carefully position the brake caliper (with inboard shoe) over the brake rotor, outboard shoe and adapter.
  6.  
  7. Install the caliper guide pin bolts and tighten to 26 ft. lbs. (35 Nm).
    NOTE
    Extreme caution should be taken not to cross thread the caliper guide pin bolts.

  8.  
  9. Install the caps over the ends of the guide pin bolts.
  10.  
  11. Install the anti-rattle spring on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
    WARNING
    When connecting the brake hose to the caliper, install the new brake hose to caliper special washers.

  12.  
  13. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to 26 ft. lbs. (35 Nm).
  14.  
  15. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of: 100 ft. lbs. (135 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the brake pedal depressor (holding) tool.
  20.  
  21. Bleed the hydraulic brake circuit to the brake caliper.
  22.  
  23. Road test vehicle to check for proper brake operation.
  24.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the front wheel and tire assembly.
  8.  
  9. Remove the anti-rattle spring from the outboard side of the caliper and adapter.
  10.  
  11. Remove the banjo bolt connecting the brake hose to the brake caliper. There are 2 washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers.
  12.  
  13. Remove the two caps in place over the caliper guide pin bolts.
  14.  
  15. Remove the two caliper guide pin bolts.
  16.  
  17. Remove the caliper from the caliper adapter and the brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed.

    Click image to see an enlarged view

    Fig. Front caliper mounting

  18.  

To install:

  1. Completely retract the caliper piston back into the piston bore of the caliper.
  2.  
  3. Lubricate both caliper adapter abutments where the shoes slide with a sufficient amount of MOPAR® Silicone Grease, or equivalent.
    NOTE
    If the pads are being transferred or newly installed, make note that the inboard brake pads are stamped L or R for left or right side of the vehicle. The P-slot or void on the piston insulator must be positioned upward when the brake caliper is mounted.


    WARNING
    Use care when installing the brake caliper assembly onto the adapter, so that the seals on the caliper guide pin bushings do not get damaged by the adapter bosses.

  4.  
  5. Carefully position the brake caliper (with inboard shoe) over the brake rotor, outboard shoe, and adapter.
  6.  
  7. Install the caliper guide pin bolts and tighten to 26 ft. lbs. (35 Nm).
    WARNING
    Extreme caution should be taken not to cross thread the caliper guide pin bolts.

  8.  
  9. Install the caps over the ends of the guide pin bolts.
  10.  
  11. Install the anti-rattle spring on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
    NOTE
    When connecting the brake hose to the caliper, install the new brake hose to the caliper special washers.

  12.  
  13. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to 26 ft. lbs. (35 Nm).
  14.  
  15. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all the nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 100 ft. lbs. (136 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the brake pedal depressor (holding) tool.
  20.  
  21. Bleed the hydraulic brake circuit to the brake caliper.
  22.  
  23. Road test the vehicle to check for proper brake operation.
  24.  

 
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