Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Brake Caliper

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surface with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

See Figure 1

Do not allow the master cylinder reservoir to empty. An empty reservoir will allow air to enter the brake system and complete system bleeding will be required.

  1. Remove about half of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle, then remove the tire and 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 or other tool.
  6.  



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Fig. Fig. 1: Loosen the brake hose-to-caliper attaching bolt

  1. If the caliper is to be completely removed from the vehicle, remove the brake hose attaching bolt, then disconnect the brake hose from the caliper and plug the hose to prevent fluid contamination or loss.
  2.  
  3. Remove the caliper mounting bolts and lift the caliper off of the support bracket.
  4.  
  5. Remove the 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.
  6.  

To install:
  1. Clean and lubricate both steering knuckle abutments or support brackets with a coating of multi-purpose 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 or support bracket. Be sure the caliper guide pin bolts, rubber bushings and sleeves are clear of the steering knuckle bosses.
  4.  
  5. On Cirrus, Stratus, Sebring convertible and Breeze models, install the caliper guide pin bolts and tighten to 16 ft. lbs. (22 Nm). On Sebring coupe and Avenger models, tighten the caliper guide pin bolts to 54 ft. lbs. (74 Nm).
  6.  
  7. On Cirrus, Stratus, Sebring convertible and Breeze models, connect the brake line hose to the caliper and tighten to 35 ft. lbs. (48 Nm). On Sebring coupe and Avenger models, connect the brake line hose to the caliper and tighten to 22 ft. lbs. (29 Nm).
  8.  
  9. Fill the master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system.
  10.  
  11. Install the wheel and tire. Tighten the lug nuts in a star pattern to 95 ft. lbs. (129 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Depress the brake pedal 3-4 times to seat the brake linings and to restore pressure in the system.
  16.  


CAUTION
Do not move the vehicle until a firm pedal is obtained.

  1. Road test the vehicle and check for proper operation.
  2.  

OVERHAUL



See Figures 2 through 9

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.
    4.  

  2.  



Click image to see an enlarged view

Fig. Fig. 2: 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. 3: Withdraw the piston from the caliper bore

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



Click image to see an enlarged view

Fig. Fig. 4: 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. 5: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 6: ... 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. 7: 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.
  6.  
  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.
  10.  



Click image to see an enlarged view

Fig. Fig. 8: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  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.  



Click image to see an enlarged view

Fig. Fig. 9: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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