Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Brake Pads

Print

INSPECTION




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.

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.

Double Pin Non-Family Caliper

See Figures 1 and 2

This front brake caliper was available on some of the 1991-93 vehicles (except Premier and Monaco) 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, mount directly to the steering knuckle by 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.  



Click image to see an enlarged view

Fig. Fig. 1: Front brake caliper mounting and brake hose connection locations



Click image to see an enlarged view

Fig. Fig. 2: Make certain to identify the brake pads before installing them on the vehicle

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 18-25 ft. 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 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11


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 double pin family front brake caliper was available on some 1988-95 vehicles, including all Premier and Monaco cars. 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 use of an adapter, to which the caliper is mounted. The family double pin caliper, therefore, mounts to an adapter with 2 through-bolts, which is mounted to the steering knuckle.

  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.  



Click image to see an enlarged view

Fig. Fig. 3: After removing the wheels, loosen the caliper slide pin bolts ...



Click image to see an enlarged view

Fig. Fig. 4: ... then remove the bolts from the caliper



Click image to see an enlarged view

Fig. Fig. 5: Pry the caliper loose from the brake rotor, then ...



Click image to see an enlarged view

Fig. Fig. 6: ... carefully lift the caliper off of the brake rotor



Click image to see an enlarged view

Fig. Fig. 7: Remove the outboard brake pad from the brake adapter and ...



Click image to see an enlarged view

Fig. Fig. 8: ... slide the brake rotor off of the axle hub



Click image to see an enlarged view

Fig. Fig. 9: The brake rotor must be removed before the inboard brake pad can be removed from the



Click image to see an enlarged view

Fig. Fig. 10: Remove the inboard brake pad from the brake adapter, along with the retaining spring



Click image to see an enlarged view

Fig. Fig. 11: Before installing the new pads, push the piston back into the caliper with a large C-clamp

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 35 ft. 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.  

 
label.common.footer.alt.autozoneLogo