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

Brake Disc (Rotor)

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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

  1. Remove about half of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle and remove the tire/wheel assembly.
  4.  
  5. Remove the 2 caliper guide pin or mounting bolts.
  6.  
  7. Lift the caliper assembly away from the brake rotor.
  8.  
  9. Support the caliper assembly 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.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the brake rotor by pulling it straight off the wheel mounting studs

  1. Remove the brake rotor by pulling it straight off the wheel mounting studs.
  2.  

To install:
  1. Completely retract the piston into the caliper using a large C-clamp or other suitable tool.
  2.  
  3. Install the brake rotor onto the wheel hub.
  4.  
  5. Install the caliper assembly over the brake rotor and install the guide pin or mounting bolts.
  6.  
  7. On Cirrus, Stratus, Sebring convertible and Breeze models, tighten the caliper guide pin bolts to 16 ft. lbs. (22 Nm). On Sebring coupe and Avenger models, tighten the support bracket bolts to 65 ft. lbs. (88 Nm).
  8.  
  9. Fill the master cylinder to the proper level with fresh brake fluid.
  10.  
  11. Install the tire/wheel assembly and lower the vehicle.
  12.  
  13. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  14.  


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

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

Inspection

Cirrus, Stratus, Sebring Convertible and Breeze

See Figures 2, 3 and 4

Whenever the brake calipers or pads are removed, inspect the rotors for defects. The brake rotor is an extremely important component of the brake system. Cracks, large scratches or warpage can adversely affect the braking system, at times to the point of becoming very dangerous.

Light scoring is acceptable. Heavy scoring or warping will necessitate refinishing or replacement of the disc. The brake disc must be replaced if cracks or burned marks are evident.



Click image to see an enlarged view

Fig. Fig. 2: Check the rotor thickness using a micrometer



Click image to see an enlarged view

Fig. Fig. 3: Check the rotor run-out using a dial indicator

Check the thickness of the disc using a micrometer. Measure the thickness at 12 equally spaced points 1 in. (25mm) from the edge of the disc. If thickness varies more than 0.0005 in. (0.013mm), the disc should be refinished, provided equal amounts are cut from each side and the thickness does not fall below 0.843 in. (21.4mm). Be sure to remove as little as necessary from each rotor side.

Check the run-out (warpage) of the disc using a dial indicator. Total run-out of the disc installed on the car should not exceed 0.005 in. (0.013mm). The disc can be resurfaced to correct minor variations, as long as equal amounts are cut from each side and the thickness is at least 0.882 inch (22.4mm) after resurfacing.



Click image to see an enlarged view

Fig. Fig. 4: Check the wheel hub run-out using a dial indicator

Check the run-out of the hub (disc removed). It should not be more than 0.002-0.003 inch (0.050-0.076mm). If so, the hub should be replaced.

All rotors have markings for MINIMUM allowable thickness cast on an unmachined surface or an alternate surface. Always use this specification as the minimum allowable thickness or refinishing limit. Refer to a local auto parts store or machine shop, if necessary, where rotors are resurfaced.

If the rotor needs to be replaced with a new part, the protective coating on the braking surface of the rotor must be removed with an appropriate solvent before installing the rotor to the vehicle.

Sebring Coupe and Avenger

Whenever the brake calipers or pads are removed, inspect the rotors for defects. The brake rotor is an extremely important component of the brake system. Cracks, large scratches or warpage can adversely affect the braking system, at times to the point of becoming very dangerous.

Light scoring is acceptable. Heavy scoring or warping will necessitate refinishing or replacement of the disc. The brake disc must be replaced if cracks or burned marks are evident.

Check the thickness of the disc using a micrometer. Measure the thickness at 8 equally spaced points approximately 45° apart and 0.39 inch (10mm) in from the outer edge of the disc. If thickness varies more than 0.0006 inch (0.015mm), the disc should be refinished, provided equal amounts are cut from each side.The rotor's thickness must not fall below 0.880 inch (22.4mm) for the front, 0.330 inch (8.40mm) for rear solid rotors, or 0.720 inch (18.4mm) for rear ventilated discs. Be sure to remove as little as necessary from each rotor side.

Check the run-out (warpage) of the disc using a dial indicator placed 0.2 inch (5mm) from the outer edge of the rotor. Total run-out of the disc installed on the car should not exceed 0.0031 inch (0.08mm). The disc can be resurfaced to correct minor variations, as long as equal amounts are cut from each side and the thickness does not exceed the minimum thickness after resurfacing.

Check the run-out of the hub (disc removed). It should not be more than 0.002 inch (0.050mm). If so, the hub should be replaced.

All brake discs or rotors have markings for MINIMUM allowable thickness cast on an unmachined surface or an alternate surface. Always use this specification as the minimum allowable thickness or refinishing limit. Refer to a local auto parts store or machine shop, if necessary, where rotors are resurfaced.

If the rotor needs to be replaced with a new part, the protective coating on the braking surface of the rotor must be removed with an appropriate solvent before installing the rotor to the vehicle.

 
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