Chrysler Colt/Vista 1990-1993 Repair Information

Disc Brake Calipers

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

REMOVAL & INSTALLATION



  1. Raise the vehicle and support it safely on stands.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Disconnect the parking brake cable at the caliper by removing the special clip at the caliper and then disconnecting the fitting located on the end of the cable.
  6.  
  7. Place a drain pan under the work area and disconnect the brake hose at the strut. Plug the open line immediately.
  8.  
  9. Remove the lock (lower) pin from the caliper assembly.
  10.  
  11. Remove the bolts mounting the caliper support to the lower strut and remove the assembly. Remove the cap and guide pin to separate the caliper from the caliper support.
  12.  
  13. Assemble the complete unit before installation. Place the unit onto the car and tighten the caliper support mounting bolts to 54 Nm or 40 ft. lbs. The guide and lock pins should be tightened to 27 Nm or 20 ft. lbs.
  14.  
  15. Reconnect the brake line securely.
  16.  
  17. Connect the parking brake cable and install the clip securely.
  18.  
  19. Bleed the system thoroughly, keeping the master cylinder reservoir supplied with fluid during and after the procedure. Make certain the brakes have the correct feel and engagement point before lowering the car to the ground.
  20.  

OVERHAUL




WARNING
The use of the correct special tools or their equivalent is REQUIRED for this procedure. Special tool MB990652 or equivalent to use in twisting the piston out of the caliper body; a steel pipe 19mm inch diameter; and special tool MB 991041 or equivalent (to remove a snapring from the caliper) will all be required.

  1. Remove the caliper and support. Separate the caliper from the support.
  2.  
  3. With the blade of a small flat instrument, remove the boot ring from the caliper body and the pull out the piston boot.
  4.  
  5. Use special tool MB 990652 or equivalent to remove the piston from the caliper with a twisting motion.
  6.  
  7. Using a 19mm diameter steel pipe to press the spring retainer or case into the caliper body, and use MB 991041 or equivalent to remove the snapring that holds the retainer. Remove the spring case, return spring, washer, and stop from the body.
  8.  
  9. Remove the automatic adjuster spindle from the body and remove the connecting link. Remove the O-ring from the adjuster spindle.
  10.  
  11. Being careful not to scratch the cylinder wall, remove the piston seal from the caliper body using a blunt, non-metallic tool.
  12.  
  13. Disconnect the return spring, remove the mounting nut, and pull the parking brake actuating lever out of the caliper assembly. Remove the rubber boot that seals the lever shaft from the caliper body.
  14.  
  15. Unscrew the guide and lock pin sleeves from the caliper body and remove their rubber boots.
  16.  
  17. Clean the piston and cylinder walls with alcohol or clean brake fluid.
  18.  

Inspect parts as follows:



Check the connecting link and spindle for excessive wear.
 
Check the body of the caliper for fatigue cracks or rust.
 
Check the spindle for rust. Check the bearing for the spindle shaft for excessive wear.
 
Check the piston and the caliper wear surfaces for scoring or corrosion.
 
Replace the piston seal.
 
Check the piston rubber boot for cracking or brittleness.
 
Replace all defective parts.
 

  1. Apply the grease in the rebuild kit (specified for use on rubber parts) to the piston seal and to the groove in the cylinder wall. Install the new seal, making sure it is installed squarely.
  2.  
  3. Apply the proper grease in the rebuild kit to the spindle bearing, spindle, shaft and lever, lever rubber boot, connecting link, self-adjuster spindle, and related locations of the caliper body. Install the connecting link so the hole in the link lines up with the hole in the bearing.
  4.  
  5. Fit the dust boot into the caliper body. Insert the spindle shaft with the groove facing the hole in the bearing. Insert the connecting link from the cylinder side.
  6.  
  7. Coat the O-ring with clean brake fluid and mount it onto the auto-adjuster spindle. Insert the auto-adjuster spindle into the caliper.
  8.  
  9. Install the stop, spring washer, spring, and spring housing or case. Complete this assembly by using the steel pipe to press the spring case inward; use the special tool (used in removal) to attach the snapring to the caliper body. Make absolutely certain that the opening in the snapring faces the bleeder screw.
  10.  
  11. Use the special tool to twist the piston into the caliper. The cylinder is threaded so that the piston cannot move in and out of the bore without a twisting motion.
  12.  
  13. Apply the specified grease to the piston boot mounting grooves in the caliper body and the piston. Install the boot squarely. Carefully install the piston boot retaining ring.
  14.  
  15. Use the correct grease to coat the interior portion of the guide and lock pin sleeves, the threads of the caliper where the sleeves screw in, the rubber boot mounting groove, and the mounting groove for the cap. Then mount the sleeves onto the caliper and insert their respective pins.
  16.  
  17. With the pins, attach the caliper to the caliper support and tighten them to 27 Nm or 20 ft. lbs. Mount the caliper support to the car and tighten the bolts to 54 Nm or 40 ft. lbs.
  18.  
  19. Rotate the parking brake cable bracket clockwise until it contacts the caliper body and tighten the bracket in that position. Reconnect the cable to the bracket.
  20.  
  21. Reconnect the brake hose securely, bleed the system of air, and make sure the brakes respond normally (caliper pistons have positioned the pads against the discs) before operating the vehicle.
  22.  

 
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