Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Unbolt the caliper and hang it with with wire or a bungee cord out of the way



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Fig. Fig. 2: Carefully tap the side of the rotor if necessary to aid in removal



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Fig. Fig. 3: Pull the rotor straight off the axle hub

  1. Loosen the lug nuts on the wheel being worked on.
  2.  
  3. Raise and safely support the vehicle. Remove the appropriate wheels.
  4.  
  5. Remove the caliper guide pin bolts and remove the caliper/brake pad assembly. Do not disconnect the brake line. Support the caliper assembly by hanging it off of the steering knuckle or strut with a strong piece of wire to prevent strain on the brake hose.
  6.  
  7. Remove the rotor from the hub assembly by pulling straight off wheel mounting studs.
  8.  
  9. Inspect the brake rotor for the maximum allowable runout. Inspect the brake rotor for excessive lining deposits or corrosion. Resurface or replace the rotor if any of these conditions apply.
  10.  

To install:
  1. Clean both sides of the brake rotor with a brake cleaning solvent. Install the brake rotor onto the hub assembly.
  2.  
  3. Install the brake caliper. If installing a new rotor, compress the caliper piston back into the caliper bore to provide clearance for the rotor. It is good practice to remove some (one-third to one-half) of the brake fluid from the master cylinder reservoir to avoid fluid overflow as the piston pushed fluid back through the brake lines into the master cylinder and reservoir.
  4.  
  5. Tighten the caliper guide pin bolts to 17 ft. lbs. (22 Nm).
  6.  
  7. Install the wheel and hand-tighten the lug nuts.
  8.  
  9. Lower the vehicle and tighten the lug nuts in a star pattern sequence to 95 ft. lbs. (129 Nm).
  10.  
  11. Pump the brakes several times to seat the brake pads against the brake rotors before attempting to move the vehicle.
  12.  
  13. Road test the vehicle to verify good brake performance.
  14.  

INSPECTION



See Figure 4



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Fig. Fig. 4: The rotor thickness is marked on the inner edge of the disc as shown

Whenever the brake calipers are removed, the brake pads are replaced, or any front axle work is performed to the vehicle, 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, and 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. 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 the equal amounts are out from each side and the thickness does not fall below 0.882 inch (22.4mm).

Check the run-out (warpage) of the disc. Total run-out of the disc installed on the car should not exceed 0.003 in. (0.08mm). 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.

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, shop where brake disc or rotors are resurfaced.

If the brake disc or 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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