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

Brake Pads

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CAUTION
Brake shoes may 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 any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

INSPECTION



See Figure 1



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Fig. Fig. 1: When inspecting the pads, measure the pad and backing plate together (between the arrows)

Measure lining wear by measuring the combined thickness of the pad and pad backing plate at the thinnest point. It must measure at least 5 / 16 in. (8mm) thick on all vehicles covered by this information.

Some vehicles are equipped with a wear sensor on the outboard pad of the front disc brake assemblies. This sensor, when emitting a squealing sound, signals that the brake linings should be inspected and may require replacement.

Always replace both front brake pad assemblies (inboard and outboard pad) on both front wheels whenever necessary. The specifications given above on front disc brake lining wear should be used as the guide for replacement.

REMOVAL & INSTALLATION




WARNING
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.

ATE-Type Brake Caliper

See Figures 2, 3, 4 and 5

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Fig. Fig. 2: After removing the attaching bolts, remove the retaining spring ...



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Fig. Fig. 3: ... then lift the caliper off of the adapter



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Fig. Fig. 4: Remove the outboard brake pad from the adapter and ...



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Fig. Fig. 5: ... remove the inboard pad from the caliper-suspend the caliper with strong wire or cord

This non-family caliper is used on some 1981-87 models. This caliper, unlike the later non-family caliper, does utilize an adapter. During the period between 1981-87, this is the only dual-pin caliper used; the single pin caliper is a Kelsey-Hayes type and is covered later in this section.

  1. Apply the parking brake, block the rear wheels, then raise and securely support the front of the vehicle on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the caliper hold-down spring by pushing in on the center of the spring and pushing outward.
  6.  
  7. Loosen, but do not remove the guide pins, until the caliper is free. Remove the guide pins only if the bushings are being replaced.
  8.  
  9. Lift the caliper away from the rotor. The inboard pad will remain with the caliper. Remove the pad by pulling it away from the caliper piston to unsnap the retaining clip.
  10.  
  11. Remove the outboard pad by simply pulling it away from the caliper adapter.
  12.  
  13. If the caliper is being removed, disconnect and cap the brake line. If only the pads are being removed, support the caliper with wire in such a way that the brake line will not be stressed.
  14.  

To install:
  1. Lubricate both bushing channels with silicone lubricant.
  2.  
  3. Remove the protective backing from the noise suppression gasket on the inner pad assembly.
  4.  
  5. Install the new inboard pad in the caliper, centering the retainer in the piston bore.
  6.  
  7. Remove the protective backing from the noise suppression gasket on the outboard pad and position the pad on the adapter.
  8.  
  9. Carefully lower the caliper over the rotor and inboard pad.
  10.  
  11. Install the guide pins and tighten to 18-22 ft. lbs. (25-30 Nm).
  12.  

It is easy to crossthread the guide pins. Start them carefully, turning them gently by hand and allowing them to find their own angle.

  1. Install the hold-down spring.
  2.  
  3. Install the wheels and tighten the lugs to 461 inch lbs. (61 Nm) in a star pattern, then tighten them to the full torque of 961 inch lbs. (129 Nm).
  4.  
  5. If the brake hose was disconnected from the caliper, bleed the system thoroughly, as described earlier in this section.
  6.  
  7. 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.
  8.  

Double Pin Non-Family Caliper

See Figures 6 and 7

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Fig. Fig. 6: Front brake caliper mounting and brake hose connection locations



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Fig. Fig. 7: Make certain to identify the brake pads before installing them on the vehicle

This front brake caliper was available on some of the 1991-93 vehicles covered by this information. The exact models equipped with these calipers, in contrast to the other double pin Kelsey-Hayes caliper, is not known. This caliper is characterized by the lack of an adapter, to which the caliper is mounted. The non-family double pin caliper, therefore, mounts directly to the steering knuckle with 2 through-bolts.

  1. Remove the master cylinder reservoir lid and remove some of the brake fluid from the master cylinder.
  2.  
  3. Slightly loosen the front wheel lug nuts.
  4.  
  5. Raise and support the front end on jackstands.
  6.  
  7. Remove the front wheels.
  8.  
  9. Remove the brake caliper assembly-to-steering knuckle attaching guide pin bolts.
  10.  
  11. Pull the lower end of the brake caliper out from the machined abutment on the steering knuckle. Then roll the caliper out and away from the rotor. The pads will remain on the caliper.
  12.  

Support the caliper with strong wire or cord from the vehicle frame to prevent the weight of the caliper from damaging the flexible hose.

  1. Remove the outboard brake pad by prying between the top of the outboard shoe and the top of the caliper assembly.
  2.  
  3. Remove the inboard pad by simply pulling it away from the caliper piston.
  4.  

To install:
  1. Thoroughly clean and lubricate both steering knuckle/brake pad contacting surfaces with a liberal amount of Mopar® Multi-purpose lubricant or equivalent.
  2.  
  3. Lubricate both bushing channels with silicone grease.
  4.  
  5. Using a large C-clamp, slowly press the caliper piston back into the caliper (until fully seated).
  6.  
  7. The inboard brake shoes are common. The outboard brake shoes are marked with either LH (left hand side) or RH (right hand side) to denote which side of the vehicle to be installed on.
  8.  
  9. Remove the protective backing from the noise suppression gasket on the inboard pad assembly.
  10.  
  11. Install the new inboard pad in the caliper, centering the retainer in the piston bore.
  12.  
  13. Remove the protective backing from the noise suppression gasket on the outboard pad and position the pad on the brake caliper.
  14.  
  15. Carefully lower the caliper over the rotor and guide hold-down spring under the machined abutment on the knuckle assembly.
  16.  
  17. Install the guide pins and torque to 18-261 inch lbs. (24-34 Nm).
  18.  

It is easy to crossthread the guide pins. Start them carefully, turning them gently by hand and allowing them to find their own angle.

  1. Install the wheels. For more details refer to Suspension & Steering .
  2.  
  3. Lower the vehicle.
  4.  
  5. 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.
  6.  

Single and Double Pin Family Caliper

See Figures 7 through 16

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Fig. Fig. 8: After removing the wheels, loosen the caliper slide pin bolts ...



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Fig. Fig. 9: ... then remove the bolts from the caliper



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Fig. Fig. 10: Pry the caliper loose from the brake rotor, then ...



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Fig. Fig. 11: ... carefully lift the caliper off of the brake rotor



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Fig. Fig. 12: Remove the outboard brake pad from the brake adapter and ...



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Fig. Fig. 13: ... slide the brake rotor off of the axle hub



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Fig. Fig. 14: The brake rotor must be removed before the inboard pad can be removed from the adapter



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Fig. Fig. 15: Remove the inboard brake pad from the brake adapter, along with the retaining spring



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Fig. Fig. 16: Before installing the new pads, push the piston back into the caliper with a large C-clamp


WARNING
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.

The Kelsey-Hayes single pin family front brake caliper was available on some 1981-87 vehicles, including all Premier, whereas the double pin Kelsey-Hayes caliper was available on 1988-95 models. The exact models equipped with these calipers is not known. These calipers are characterized by the use of an adapter, to which the caliper is mounted. The Kelsey-Hayes calipers, therefore, mount to adapters with 2 through-bolts, which is mounted to the steering knuckle. The 1981-87 single pin caliper is characterized by the single pin; all other calipers used at that time utilize a dual pin design.

  1. Remove the master cylinder reservoir lid and remove some of the brake fluid from the master cylinder.
  2.  
  3. Slightly loosen the wheel lug nuts.
  4.  
  5. Raise and support the front end of the vehicle on jackstands.
  6.  
  7. Remove the front wheels.
  8.  
  9. Remove the caliper guide pin bolt(s), by loosening them until they are free from the threads then pull them out of the caliper adapter.
  10.  
  11. Using a small prybar, gently wedge the caliper away from the rotor, breaking the adhesive seals.
  12.  
  13. Slowly slide the caliper away from the rotor and off the caliper adapter. Support the caliper securely by hanging it from the body with wire (this is necessary to keep its weight from damaging the brake hose).
  14.  
  15. Slide the outboard pad off the caliper adapter. Then remove the disc by simply sliding it off the wheel studs.
  16.  
  17. Remove the inboard pad by sliding it off the caliper adapter.
  18.  

To install:
  1. Lubricate both bushing channels with silicone grease.
  2.  
  3. Using a large C-clamp, slowly press the caliper piston back into the caliper (until fully seated).
  4.  
  5. Remove the protective paper backing from the anti-squeal surfaces on both pads. Install the inboard pad on the adapter. Be careful to keep grease from the bushing channels from getting onto the pad as you do this.
  6.  
  7. Install the rotor onto the wheel studs of the steering knuckle. Install the outboard pad in the caliper.
  8.  
  9. Remove the caliper from the hanger. Lower the caliper into position over the rotor and pads. Install the guide pin bolt(s) and torque them to 361 inch lbs. (48 Nm).
  10.  

It is easy to crossthread the guide pin. Start it carefully, turning it by hand gently and allowing it to find its own angle.

  1. Install the wheels.
  2.  
  3. Lower the vehicle.
  4.  
  5. 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.
  6.  

 
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