Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Brake Disc (Rotor)



On vehicles equipped with a Bendix Type 6 Anti-lock Brake System (ABS), a Diagnostic Readout Box (DRB or DRB II) is necessary for brake system bleeding. Failure to use a DRB to bleed the system will lead to system failure. Refer to the ABS portion of this section for bleeding procedures and precautions.

  1. Raise and support the front end on jackstands.
  3. Remove the caliper from the rotor, but do not disconnect the brake line.
  5. Suspend the caliper out of the way with wire. Do not put stress on the brake hose.
  7. Remove the rotor (some applications have 2 hold down in the brake disc or rotor screws that must be removed) from the drive flange studs.

To install:
  1. Coat both sides of the rotor with alcohol or equivalent (to clean assembly) and slide it onto the studs.
  3. Install the caliper. For more details, refer to the caliper installation procedure earlier in this section.
  5. Install the wheels. Tighten the lug nuts until snug.
  7. Lower the vehicle.
  9. Tighten the lug nuts to the specified torque in the torque specifications chart in Suspension & Steeringzwqfxcsdszryfasqczfdsscqwcsecbx .
  11. Pump the brake pedal several times to ensure that the brake pads seat against the rotor. The pedal must give resistance at the normal position before attempting to drive the car. Drive the car at moderate speeds in an isolated area in order to apply the brakes several times to test the system and seat the new linings.


See Figures 1, 2 and 3

Click image to see an enlarged view

Fig. Fig. 1: Use Special Tool C-3339 or its equivalent to measure the run-out (warpage/wobble) of the front disc brake rotors

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Fig. Fig. 2: After checking the rotor for run-out, measure the axle hub in the same manner

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Fig. Fig. 3: The minimum allowable thickness of the brake rotors is stamped on a flat on the rotor itself

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 equal amounts are out from each side and the thickness does not fall below 0.882 inch (22.4mm) on Chrysler front wheel drive vehicles.

Check the run-out (warpage) of the disc. 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) on Chrysler front wheel drive vehicles after resurfacing.

Check the run-out of the hub (disc removed). It should not be more than 0.002-0.003 inch (0.050-0.076mm) on Chrysler front wheel drive vehicles 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, 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.