Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Brake Pads

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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:
    NOTE
    On some models you will have to remove the guide and lock pins and on others the caliper unbolts from the guide and lock pins.


    NOTE
    On some models the caliper can be flipped up by leaving the lock (upper) pin in place, using it as a pivot point.



    Some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
     
    Tire and wheel
     
    Caliper bolts and lift the caliper assembly from the caliper support.
     



    Tie the caliper out of the way using wire. Do not allow the caliper to hang by the brake line.
     



    Brake pads, spring clip and shims. Take note of positioning to aid installation.
     

  4.  
  5. Install the wheel lug nuts onto the studs and lightly tighten. This is done to hold the disc on the hub.

    Click image to see an enlarged view

    Fig. Exploded view of the front brake pads and related components

  6.  

To install:

  1. Use a brake caliper piston compressor or large C-clamp to compress the piston back into the caliper bore.
  2.  
  3. Install or connect the following:
    NOTE
    Some brake pads have pre-installed anti-squeal shims, some have self-adhesive shims and some require grease on the shims.


    CAUTION
    Pump brake pedal several times, until firm, before attempting to move the vehicle.



    Brake pads, shims and spring clip onto the caliper support, after lubricating the slide pins
     
    Caliper over the brake pads
     



    Lubricate caliper guide and lock pins in their original positions. Torque guide and locking pins to 74 ft. lbs. (100 Nm). On models that use a smaller bolt to hold the caliper to the pins, torque those bolts to 28 ft. lbs. (38 Nm).
     
    Tire and wheel
     

  4.  
  5. Road test the vehicle and check brakes for proper operation.
  6.  

  1. Remove the about half of the brake fluid from the master cylinder.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 caliper-to-steering knuckle guide pin bolts.
  6.  
  7. Lift the caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then slide the opposite end of the caliper out from under the machined end of the steering knuckle.
    WARNING
    Supporting weight of caliper by the flexible brake fluid hose can damage the hose.

  8.  
  9. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose which will damage the hose.
  10.  
  11. Remove the brake pads from the caliper. Remove the outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then slide the pad down and off the caliper. Pull the inboard brake pad away from the piston until the retaining clip is free from the cavity in the piston.

    Click image to see an enlarged view

    Fig. Disc brake pad identification

  12.  

To install:

  1. Completely depress the piston into the caliper using a large C-clamp or other suitable tool.
  2.  
  3. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease.
  4.  
  5. Install the new inboard brake pad into the caliper piston by firmly pressing into the piston bore. Install the brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake pad assembly is positioned squarely against the face of the caliper piston.
    NOTE
    Be sure to remove the noise suppression gasket paper cover if the pads come so equipped.

  6.  
  7. Install the new outboard brake pad onto the caliper assembly.
  8.  
  9. Carefully position the caliper and brake pad assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
  10.  
  11. 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).
  12.  
  13. Reinstall the wheel and tire. Torque the lug nuts in 2 steps, in a star pattern sequence to 95-100 ft. lbs. (129-135 Nm).
  14.  
  15. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  16.  
  17. Check and adjust brake fluid level as necessary.
  18.  
  19. Road test vehicle to check for proper brake operation.
  20.  

  1. Remove the about half of the brake fluid from the master cylinder.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove the both front wheel and tire assemblies.
  6.  
  7. Remove the anti-rattle spring from the outboard side of the caliper and adapter.
  8.  
  9. Remove the two caps in place over the caliper guide pin bolts.
  10.  
  11. Remove the two caliper guide pin bolts.
  12.  
  13. 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.
    WARNING
    Supporting weight of caliper by the flexible brake fluid hose can damage the hose.

  14.  
  15. Using wire or cord, hang the caliper from the front strut assembly. Support the caliper firmly to prevent weight of caliper from being supported by the brake fluid hose.
  16.  
  17. Remove the outboard brake pad from the caliper adapter.
  18.  
  19. Pull the inboard brake pad away from the caliper piston until the retaining clip on shoe is free from the cavity in the caliper piston.
  20.  
  21. Repeat the above procedure on other side of the vehicle.

    Click image to see an enlarged view

    Fig. Removing inboard pad



    Click image to see an enlarged view

    Fig. Inboard shoe orientation

  22.  

To install:


NOTE
There may be more than one lining material released. Make sure proper linings are being installed.

  1. Begin on one side of the vehicle or the other.
  2.  
  3. Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake pads installed).
  4.  
  5. If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake pad assemblies.
    NOTE
    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.

  6.  
  7. Install the new inboard brake pad into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake pad is positioned squarely against the face of the caliper piston.
  8.  
  9. Lubricate both adapter abutments where the shoes slide with a small amount of MOPAR® Silicone grease, or equivalent.
  10.  
  11. Slide the new outboard brake pad into the caliper adapter with the lining up against the outside of the brake rotor.
    WARNING
    Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses.

  12.  
  13. Carefully position the brake caliper over the brake rotor and adapter.
  14.  
  15. Install the caliper guide pin bolts and tighten to 26 ft. lbs. (35 Nm). Extreme caution should be taken not to cross thread the caliper guide pin bolts.
  16.  
  17. Install the caps over the caliper guide pin bolts.
  18.  
  19. Install the new caliper hold-down spring (anti-rattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
  20.  
  21. Repeat the above procedure on other side of the vehicle.
  22.  
  23. Install the wheel and tire assemblies. Tighten the wheel mounting 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).
  24.  
  25. Lower vehicle.
  26.  
  27. Pump the brake pedal several times. This will set the shoes to the brake rotor.
  28.  
  29. Check and adjust brake fluid level as necessary.
  30.  
  31. Road test vehicle to check for proper brake operation.
  32.  


NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove about half of the brake fluid from the master cylinder.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the front wheel and tire assemblies.
  8.  
  9. Remove the anti-rattle spring from the outboard side of the caliper and adapter.
  10.  
  11. Remove the 2 caps in place over the caliper guide pin bolts.
  12.  
  13. Remove the 2 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.
    WARNING
    Supporting the weight of caliper by the flexible brake fluid hose can damage the hose.

  16.  
  17. Using a mechanics wire or cord, hang the caliper from the front strut assembly. Support the caliper firmly to prevent the weight of caliper from being supported by the brake fluid hose.
  18.  
  19. Remove the outboard brake pad from the caliper adapter.
  20.  
  21. Pull the inboard brake pad away from the caliper piston until the retaining clip on the shoe is free from the cavity in the caliper piston.
  22.  
  23. Repeat the above procedure on other side of the vehicle.

    Click image to see an enlarged view

    Fig. Removing inboard pad



    Click image to see an enlarged view

    Fig. Inboard shoe orientation

  24.  

To install:


NOTE
There may be more than one lining material released. Make sure proper linings are being installed.

  1. Begin on one side of the vehicle or the other.
  2.  
  3. Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake pads installed).
  4.  
  5. If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake pad assemblies.
    NOTE
    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.

  6.  
  7. Install the new inboard brake pad into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake pad is positioned squarely against the face of the caliper piston.
  8.  
  9. Lubricate both adapter abutments where the shoes slide with a small amount of MOPAR® Silicone grease, or equivalent.
  10.  
  11. Slide the new outboard brake pad into the caliper adapter with the lining up against the outside of the brake rotor.
    WARNING
    Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses.

  12.  
  13. Carefully position the brake caliper over the brake rotor and adapter.
  14.  
  15. Install the caliper guide pin bolts and tighten to 26 ft. lbs. (35 Nm). Extreme caution should be taken not to cross thread the caliper guide pin bolts.
  16.  
  17. Install the caps over the caliper guide pin bolts.
  18.  
  19. Install the new caliper hold-down spring (anti-rattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
  20.  
  21. Repeat the above procedure on other side of the vehicle.
  22.  
  23. Install the wheel and tire assemblies. Tighten the wheel mounting 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).
  24.  
  25. Lower the vehicle.
  26.  
  27. Pump the brake pedal several times. This will set the shoes to the brake rotor.
  28.  
  29. Check and adjust the brake fluid level as necessary.
  30.  
  31. Road test the vehicle to check for proper brake operation.
  32.  

 
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