Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Brake Caliper

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Removal & Installation



Not for Dodge Stratus Sedan

Unlike many rear disc brake designs, this system does not incorporate the parking brake system into the rear brake caliper. The rear brake system is serviced similarly to the front system.

  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 C-clamp.

    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 rear brake caliper mounting

     

  6.  

To install:

  1. Install or connect the following:

    Caliper on the support bracket, lubricate and install the guide pin and lock pin. Torque the bolts to 28 ft. lbs. (38 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.  


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

  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 vehicle.
  4.  
  5. Remove the rear wheel and tire from vehicle.
  6.  
  7. 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.
  8.  
  9. Remove the 2 guide pin bolts mounting the caliper to the adapter.
  10.  
  11. Remove the caliper from adapter and rotor by first rotating top of caliper away from the adapter, then lifting the caliper off lower machined abutment on adapter.

    Click image to see an enlarged view

    Fig. Rear caliper mounting-2005 Models



    Click image to see an enlarged view

    Fig. Rear caliper removal-2005 Models

  12.  

To install:

  1. Completely retract caliper piston back into piston bore of caliper assembly.
  2.  
  3. Lubricate both adapter abutments with a liberal amount of MOPAR® Multipurpose Lubricant, or equivalent.
  4.  
  5. If removed, install the rotor on the hub making sure it is squarely seated on the face of the hub.
    WARNING
    Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter.

  6.  
  7. Carefully lower caliper and brake pads over rotor reversing the removal procedure. Make sure that the caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses.
    WARNING
    Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed.

  8.  
  9. Install the caliper guide pin bolts. Tighten the caliper guide pin bolts to 16 ft. lbs. (22 Nm).
  10.  
  11. 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).
  12.  
  13. Install the wheels and tire assembly.
  14.  
  15. 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 vehicle.
  18.  
  19. Remove the brake pedal depressor (holding) tool.
  20.  
  21. Bleed the hydraulic brake system.
  22.  
  23. Road test vehicle to check for proper brake operation.
  24.  

 
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