Chrysler Caravan/Voyager/Town and Country 1996-1999

Brake Caliper

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: If the caliper is going to be removed for overhaul, remove the brake hose



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Fig. Fig. 2: The banjo bolt uses copper gaskets on each side of the hose fitting; they should be replaced whenever the bolt is removed

  1. Raise and safely support the vehicle. Remove the wheels.
  2.  
  3. If the caliper is only being removed from the bracket (as for a brake pad change), move to Step 3. If the caliper is being removed from the vehicle (as for replacement or an overhaul and reseal), remove the brake hose attaching bolt from the caliper. Remove the hose from the caliper and discard the washers. New seal washers will be required at assembly. Plug the brake hose to prevent fluid leakage.
  4.  
  5. Remove the caliper guide pin bolts that secure the caliper to the steering knuckle.
  6.  
  7. Remove the caliper by slowly sliding it away from the steering knuckle. Slide the opposite end of the brake caliper out from under the machined abutment on the steering knuckle.
  8.  



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Fig. Fig. 3: The caliper is attached to the steering knuckle with two bolts



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Fig. Fig. 4: The bolts secure the sliding pins to the steering knuckle

  1. Using a strong piece of wire, support the brake caliper assembly off the strut unit. Do NOT allow the caliper to hang from the brake fluid flex hose or damage to the hose will result.
  2.  

To install:
  1. Clean both steering knuckle abutment surfaces of any dirt, grease or corrosion. Then lubricate the abutment surfaces with a liberal amount of MOPAR® Multipurpose Lubricant, or equivalent.
  2.  
  3. Properly position the brake caliper over the brake pads and disc rotor. Be careful not to allow the caliper seals or guide pin bushings to get damaged by the steering knuckle bosses. Install the caliper guide pin bolts and torque to 16 ft. lbs. (22 Nm). Be careful not to cross thread the guide pin bolts.
  4.  
  5. If removed, attach the brake hose to the caliper using new washers. Tighten the banjo bolt to 35 ft. lbs. (47 Nm).
  6.  



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Fig. Fig. 5: Once the two bolts are removed, the caliper can be lifted from the disc and steering knuckle



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Fig. Fig. 6: Rear disc brake calipers are mounted in the same manner as front calipers

  1. Bleed the brake system.
  2.  
  3. Install the front wheels and lug nuts. Torque the lug nuts, in a star pattern sequence, to half torque specifications. Then repeat the tightening sequence to the full torque specification of 95 ft. lbs. (129 Nm). Lower the vehicle.
  4.  
  5. Pump the brake pedal several times to insure that the brake pedal is firm. Road test the vehicle.
  6.  

OVERHAUL



See Figures 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 and 17



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Fig. Fig. 7: Exploded view of a front disc brake caliper assembly

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

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      Fig. Fig. 8: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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      Fig. Fig. 9: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



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Fig. Fig. 10: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 11: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 12: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 13: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
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  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
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Fig. Fig. 14: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing



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Fig. Fig. 15: Before mounting the caliper onto the steering knuckle, remove the sliding pins ...



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Fig. Fig. 16: ... and lubricate them with the grease supplied with the rebuild kit

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 17: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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