- Loosen the front wheel lug nuts slightly. Raise and support the front of the vehicle safely on jackstands.
- Remove the front wheels.
- When the front wheels are removed, the cutout built into the caliper housing will be exposed. Look through the opening and check the lining thickness of the inner and outer pads.
- If a visual inspection does not give a clear picture of lining wear, a physical check will be necessary.
- Refer to the procedure covering pad removal and installation for instructions.
REMOVAL & INSTALLATION
Kelsey-Hayes Single Pin Type
See Figures 1, 2, 3, 4, 5, 6, 7 and 8
Three anti-rattle clips are provided on each brake caliper, take note of locations for installation purposes.
- Loosen the wheel lug nuts slightly. Raise and safely support the front of the vehicle on jackstands.
- Remove the front wheel and tire assemblies.
- Siphon about one quarter of the brake fluid from the master cylinder and replace the cover caps.
- Using the proper size socket wrench, remove the threaded caliper guide pin.
- Insert a small prybar between the front edge of the caliper and the adapter rail. Apply steady upward pressure to loosen the adhesive seals.
Do not use a C-clamp to retract the plastic composition piston or damage to the piston could result.
- Remove the caliper by slowly sliding it up and off the adapter and disc rotor.
- Support the caliper by hanging it out of the way on wire. Do not allow the caliper to be supported by the brake hose.
- Observe the location of the anti-rattle clips. One clip is on the top of the inboard (closes to axle) brake pad. Another clip is on the bottom of the outboard brake pad, and the third is installed on the top finger of the caliper.
- Slide the outboard brake pad from the adapter and remove the brake disc rotor if necessary.
- Remove the inboard pad.
- Measure the brake lining and pad thickness. If the combined thickness at the thinnest point of the is 1 / 8 in. (3mm) or less replace both front wheel brake pad assemblies.
- Check around the caliper piston and boot for signs of brake fluid leakage. Inspect the dust boot around the caliper piston for cuts and breaks. If the boot is damaged or fluid leakage is visible, the caliper should be serviced. Check the adapter and caliper mounting surfaces for rust and dirt, clean them with a wire brush.
- Remove the protective paper from the gaskets mounted on the metal part of the brake pads.
- Install the anti-rattle clips in position.
- Install inner brake pad on the adapter.
- Install the brake disc rotor and outer brake pad.
- Press the caliper back into the caliper until it bottoms. If may be necessary to place a small piece of wood on the piston and use a C-clamp to retract the piston. If so, tighten the clamp with slow steady pressure. Stop when resistance is felt.
- Lower the caliper over the brake pads and disc rotor.
- Install the caliper guide pin, then tighten to 25-35 ft. lbs. (34-48 Nm). Take care not to cross thread the guide pin.
- After both calipers have been installed, fill the master cylinder and bleed the brakes if the caliper were rebuilt. If the calipers were not serviced, pump the brakes until a firm brake pedal is obtained.
- Install the front wheels and lower the vehicle.
- After the vehicle is lowered, check the lug nut torque, then tighten to required specification to 95 ft. lbs. (130 Nm).
- Road test the vehicle and make several firm but not hard stops to wear off any dirt from the pads or rotor.
See Figures 9, 10, 11, 12, 13, 14 and 15
The caliper is equipped with one hold-down spring running across the outboard fingers of the caliper, and is also equipped with an inner shoe to piston mounting clip.
- The Kelsey-Hayes double pin type caliper uses two mounting pins. Loosen the wheel lugs slightly.
- Raise and safely support the front of the vehicle.
- Remove the wheel and tire assembly.
- Loosen, but do not remove the two steel caliper guide pins. Back the pins out until the caliper can be moved freely.
- Pull the lower end of the caliper out from the steering knuckle support. Roll the caliper up and away from the disc rotor. The disc brake pads will remain located in their caliper positions.
- Take care, while servicing the pads, that strain is not put on the brake hose.
- Pry the outboard pad toward the bottom opened end of the caliper. The pad is retained by a captive clip. Remove the pad.
- Remove the inboard pad by pulling it outward from the caliper piston. It is retained by a captive clip.
- Inspect the caliper. Check for piston seal leaks and boot damage. Service the caliper as required.
- Press the caliper piston slowly back into the caliper bore. Use a small block of wood and a C-clamp, if necessary. Tighten the clamp slowly, and make sure the piston is not cocked. Gently bottom the piston in the caliper.
- The inboard pads are interchangeable, the outboard pads are marked with an L or R relating to the side of the vehicle they are to be used on.
- Place the inboard pad clip into the caliper piston and push into position on the piston.
- Place the outboard pad retainer clip over the ears of the caliper and slide the pad into position. If the replacement pads are equipped with a noise suppression gasket, remove the protective paper from the gasket before installation.
- Lower the caliper over the disc rotor and align the hold-down spring under the machined surface of the steering knuckle. Install the caliper mounting pins, take care not to cross thread, then tighten the pins to 18-26 ft. lbs. (25-35 Nm). Pump the brake pedal several times to move the pads against the rotor. If the caliper has been rebuilt, or other system service completed, bleed the brake system.
- Install the wheel and tire assembly. Lower the vehicle. Do not move the vehicle until a firm brake pedal is verified.
See Figures 16, 17, 18, 19, 20, 21, 22 and 23
- Raise vehicle on jackstands or centered on a hoist. See General Information & Maintenance for hoisting information.
- Remove front wheel and tire assemblies.
- Reach to the inside of the caliper assembly and pull it outboard as far as you can. This will push piston back into bore of caliper, making removal of caliper from adapter easier.
- Remove caliper guide pin bolts.
- After removing the caliper guide pin bolts lift the caliper assembly away from the braking disc with a pry bar.
- Remove the caliper assembly from braking disc and adapter by sliding the assembly out and away from the braking disc and adapter.
- Support the caliper firmly to prevent the weight of the caliper from damaging the flexible brake hose.
- Remove the outboard brake shoe assembly from the caliper adapter.
- Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs.
- Remove the inboard brake shoe assembly by sliding it out along the bottom adapter abutment until the brake shoe assembly loosens from the anti-rattle clip.
- Remove the anti-rattle clip from the top adapter abutment.
- Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter abutment rails, remove it using a wire brush do not sand rails.
- Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.
- Install the anti-rattle clip on the upper abutment of the caliper mounting adapter.
- Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies, if equipped.
- Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter abutments. Be careful not to get any grease from the adapter abutment on the surface of the brake lining material. Ensure the inboard brake shoe assembly is correctly positioned against anti-rattle clip.
- Reinstall the braking disc on the hub, by installing it over the wheel studs until it is seated against the face of the hub.
- Slide the new outboard brake shoe assembly on the adapter abutment.
- Carefully lower the caliper over the braking disk and brake shoe assemblies. Make sure that the caliper guide pin bolt, bushings and sleeves are clear of the adapter.
- Install the caliper guide pin bolts, then tighten them to 25-35 ft. lbs. (34-48 Nm). Extreme caution should be taken not to cross the threads of the caliper guide pin bolts.
- Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are tightened to half specification. This is important. Then repeat the tightening sequence to the full specified torque of 95 ft. lbs. (130 Nm).
- Remove jackstands or lower the hoist.
- Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle.
- Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.