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

Brake Caliper

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REMOVAL & INSTALLATION



Except Premier and Monaco
1988 MODELS

See Figures 1, 2, 3, 4 and 5


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.



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Fig. Fig. 1: Exploded view of the rear disc brake assembly-1988 models (except Premier and Monaco)

You'll need a metric size Allen wrench (4mm) to perform this operation.



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Fig. Fig. 2: Before disassembling the caliper components, familiarize yourself with their location and mounting position



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Fig. Fig. 3: When the caliper is lifted off of the rear disc, the outboard pad will remain on the brake adapter



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Fig. Fig. 4: Mount the new outboard pad on the brake adapter and the new inboard pad on the caliper



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Fig. Fig. 5: The brake pads are easily identifiable by their backside markings

  1. Slightly loosen the rear wheel lug nuts.
  2.  
  3. Raise rear of the vehicle and support it securely on jackstands.
  4.  
  5. Remove the rear wheels.
  6.  
  7. There is an access plug on the inboard side of the caliper that looks like an ordinary bolt. It is located just under the parking brake cable lever. Clean the plug and the area around it to keep dirt out of the caliper and then remove it.
  8.  
  9. Install the 4mm Allen wrench into the access hole and turn it counterclockwise to retract the pads from the disc. Turn the retractor a few turns: just until there is daylight between the disc and the pads.
  10.  
  11. Remove the anti-rattle spring by prying it off the outside of the caliper with a small, blunt instrument. Be careful to pry outward on the spring only far enough to release it; if the spring is pryed excessively, it may be damaged.
  12.  
  13. Clean the guide pin heads and the areas around them of dirt, then loosen them. Pull them out just far enough to free the caliper from the adapter, if it is not necessary to replace the caliper bushings. If the bushings are to be replaced, remove the guide pins completely.
  14.  
  15. Lift the caliper (and the inboard pad, which will remain with it) upward and away from the braking disc and then suspend it securely on a piece of wire to prevent putting excessive stress on the brake hose.
  16.  
  17. Pull the inboard pad away from the caliper piston to remove it. Pull the outboard pad off of the caliper adapter.
  18.  

In the following step, be careful to retract the piston very slowly and carefully and by using only a minimum of force. The use of excessive force will damage the retraction and actuation shafts.

  1. Insert the Allen wrench into the rear access hole and retract the piston all the way by turning the wrench very gently and only until the rotating effort very slightly increases.
  2.  
  3. Disconnect the brake line from the caliper, then immediately plug the brake line.
  4.  
  5. Remove the brake caliper from the vehicle.
  6.  

To install:
  1. Install a new inboard brake pad to the bore of the caliper piston. Then, install a new outboard pad, marked with either an L or R , according to the side of the vehicle you are working on. This pad is installed by sliding it onto the caliper adaptor.
  2.  
  3. Lower the caliper over the disc and outboard pad. Gently and cautiously turn the guide pins in order to start them in their threads without cross-threading them. Use a minimum amount of force and allow the pins to find their own angle so the threads will not be damaged. Tighten the guide pins to 18-26 ft. lbs. (25-35 Nm).
  4.  
  5. Install the anti-rattle spring onto the caliper. Then, insert the Allen wrench through the access hole and turn the retraction shaft clockwise (viewing from the inboard side) just until there is a slight amount of tension felt, and the clearance between the pads and disc is removed. Then, loosen (counterclockwise) the shaft 1 / 3 (120°) turn.
  6.  
  7. Attach brake line to the rear brake caliper. Tighten the rear brake line fitting to 16 ft. lbs. (22 Nm). Bleed the brake system.
  8.  

New seal washers must always be used when installing the brake hose to the caliper.

  1. Install the rear wheels and install the lug nuts until snug.
  2.  
  3. Lower the vehicle and tighten the lug nuts to the specified torque listed in the specification chart in Suspension & Steering .
  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.
  6.  

1989-95 MODELS

See Figures 6, 7 and 8


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.

All brake pins, shims and other parts removed must be reinstalled in the the proper location. Record their locations before removing any brake hardware. On vehicles equipped with ABS, refer to the necessary service procedures later in this section.



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Fig. Fig. 6: After removing the wheels, loosen and remove the 2 attaching bolts from the caliper assembly



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Fig. Fig. 7: Install the inboard pad into the caliper so that the retaining clip is inserted into the piston bore



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Fig. Fig. 8: When the outboard pad is installed into the caliper, make sure that the retaining clip arms are seated correctly on the caliper fingers

  1. Remove some of the fluid from the master cylinder.
  2.  
  3. Slightly loosen the rear wheel lug nuts.
  4.  
  5. Raise the vehicle and support safely on jackstands.
  6.  
  7. Remove the rear wheels.
  8.  
  9. Remove the hold-down spring, if equipped.
  10.  
  11. Remove the caliper mounting pin bolts. Lift the caliper off the rotor assembly.
  12.  
  13. Remove the outboard pad by prying the shoe retaining clip over the raised area of the caliper. Slide the pad down and off of the caliper.
  14.  
  15. Pull the inboard pad away from the piston until the retaining clip is free from the piston cavity.
  16.  

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. If the caliper is to be overhauled (rebuilt), perform the following:
    1. Place a small piece of wood between the piston and caliper fingers.
    2.  
    3. Carefully depress the brake pedal to hydraulically push the piston out of the bore. The brake pedal will fall away when the piston has passed the bore opening. Then prop the brake pedal to any position below the first inch (25mm) of pedal travel: this will prevent the loss of brake fluid from the master cylinder.
    4.  
    5. If both rear calipers are to be removed and overhauled, disconnect the flexible brake line at the frame bracket after removing the piston. Plug the brake tube and remove the piston from the opposite caliper, using the same process as above for the first piston removal.
    6.  
    7. Disconnect the flexible brake hose from the caliper.
    8.  
    9. For the overhaul, mount the caliper in a bench-mounted vise.
    10.  

  2.  


CAUTION
Under no condition should air pressure be used to remove the piston from the caliper bore. Personal injury could result.

  1. If the caliper is simply going to be replaced with a new one, disconnect the flexible brake hose from the caliper. Immediately plug the brake hose, to stop any brake fluid leakage and keep the fluid from becoming contaminated.
  2.  

To install:
  1. Connect the brake tube to the caliper. Tighten the brake hose-to-caliper banjo bolt to 24 ft. lbs. (33 Nm).
  2.  

New seal washers must always be used when installing the brake hose to the caliper.

  1. Use a large C-clamp, slowly compress the piston back into the caliper bore.
  2.  
  3. Install the inner pad to the caliper by centering the retaining clamp in the caliper piston bore and seating the pad against the piston.
  4.  
  5. Install the outer pad by sliding the retaining clip over the caliper fingers. Be sure that the brake pad is installed on the caliper so that the retaining clip is past the raised area on the caliper fingers.
  6.  
  7. Position the caliper over the rotor so the caliper engages the adaptor correctly (the lower tabs on the brake pads and the casting projections on the caliper are under the adapter rail). Tighten the guide pin bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install the hold-down spring, if removed.
  10.  
  11. Refill the master cylinder as necessary.
  12.  
  13. Install the rear wheels and install the lug nuts until snug.
  14.  
  15. Lower the vehicle and tighten the lug nuts to the specified torque listed in the specification chart in Suspension & Steering .
  16.  
  17. 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.
  18.  

Premier and Monaco

See Figures 9, 10, 11, 12, 13 and 14


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.

Special Tool 6366 (Spanner) or equivalent will be needed to perform this procedure.



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Fig. Fig. 9: Exploded view of the rear disc brake components-Premier and Monaco



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Fig. Fig. 10: Before removing the operating lever, matchmark the drive disc and lever



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Fig. Fig. 11: After removing the operating lever from the parking brake cable, remove the cable from the cable mounting flange



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Fig. Fig. 12: Use a pin punch to push the shoe retaining pin out of the caliper



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Fig. Fig. 13: This special tool (6366), or equivalent, is needed to retract the caliper piston-do NOT use a C-clamp to perform this



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Fig. Fig. 14: Temporarily mount the caliper to the axle to reseat the piston with the special tool and a socket wrench

  1. Slightly loosen the rear wheel lug nuts.
  2.  
  3. Raise and safely support vehicle on jackstands.
  4.  

Do not attempt to press the caliper piston back into the bore at this time.

  1. Remove wheel and tire assemblies.
  2.  
  3. Disconnect the brake hose from the caliper. Discard the 2 seal washers.
  4.  
  5. Unseat the operating lever return spring at the caliper.
  6.  
  7. Remove the operating lever attaching bolt. If reinstalling the original caliper, mark the position of the operating lever before removal. Use paint or scribe to mark the caliper drive disc and operating lever.
  8.  
  9. Pry the lever off of the drive disc.
  10.  
  11. Remove the operating lever and return spring from the parking brake cable. Replace the return spring if it is warped, bent or distorted.
  12.  
  13. Pull the parking brake cable out of the mounting flange.
  14.  
  15. Remove upper caliper slide pin with an Allen wrench.
  16.  
  17. Loosen the lower slide pin and tilt the caliper rearward. Do not remove the slide pin completely at this time.
  18.  
  19. Remove the brake pad retaining pin with a pin punch. Check the condition of the sleeves on the pin. Replace the pin if corroded, or if the sleeves are worn or damaged.
  20.  
  21. Remove the lower slide pin completely and lift the caliper off of the rotor.
  22.  
  23. Remove the anti-rattle spring.
  24.  

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

To install:

WARNING
If installing the original caliper, the rear caliper piston must be seated (bottomed) to compensate for new brake pad lining thickness. However, because the parking brake self-adjuster mechanism is attached to the piston, a specific seating method is required. The only acceptable method is by rotating the piston back into the bore with Spanner, Special Tool 6366 (or equivalent) as described in this procedure. Any other seating method will damage the self-adjuster mechanism.

  1. If reinstalling the original caliper, reseat the caliper piston in the bore as follows:
    1. Temporarily mount the caliper on the rear axle shaft. Install and tighten the caliper slide pins just enough to hold the caliper in place.
    2.  
    3. Assemble a 3 / 8 in. drive extension, ratchet wrench and a 7 / 16 in. deep socket.
    4.  
    5. Insert the spanner tool into the deep socket.
    6.  
    7. Insert the spanner tool lugs into the matching holes in the caliper piston face.
    8.  

  2.  

A lot of force is required to be exerted against the piston while using the spanner tool to start the process of piston retraction.

  1. Remove the caliper from the rear axle.
  2.  
  3. Install the brake pads and anti-rattle spring. Lubricate the caliper slide pins and bushings with silicone lubricant and install the caliper assembly. Tighten the smaller diameter guide pin to 22 ft. lbs. (30 Nm) and the larger diameter guide pin to 36 ft. lbs. (48 Nm).
  4.  
  5. Install the anti-rattle spring. Be sure the spring is positioned so that the brake pad retaining pin will go through the brake pads and the loops at each end of the anti-rattle spring.
  6.  
  7. Install the brake pad retaining pin.
  8.  
  9. Insert the parking brake cable into the caliper flange.
  10.  
  11. Position the return spring on the caliper.
  12.  
  13. Install the operating lever on the parking brake cable.
  14.  
  15. Pull the parking brake cable rearward and install the operating lever on the caliper drive disc.
  16.  
  17. Before installing the return spring, note the return spring ends. The rounded end goes on the operating lever. The square end goes on the caliper.
  18.  
  19. Connect the return spring. Connect the spring to the operating lever first, then hook the spring onto the caliper with a log prytool.
  20.  
  21. Position the new seal washers on the brake hose fitting and connect the fitting to the caliper. Tighten the fitting bolt to 22 ft. lbs. (30 Nm).
  22.  
  23. Install the rear wheels.
  24.  
  25. Lower the vehicle.
  26.  
  27. Bleed the brakes after installation. Pump the brake pedal to seat the brakes before moving vehicle.
  28.  

OVERHAUL



See Figures 15 and 16

Rear disc brake calipers are not overhauled, but are replaced on most vehicles. Check with local Auto Supply store or Dealership for the availability of service related parts. Only the dust boots and guide pin bushings are serviced, as described here. If a new caliper assembly complete with dust boots and guide pin bushings is to be installed, make sure to transfer usable pads and related parts and replace those which are worn.

  1. Disconnect and plug the brake line. Disconnect the parking brake cable retaining clips from the hanger bracket and caliper. Disconnect the cable at the parking brake lever. Then, remove the caliper.
  2.  
  3. Check the caliper dust boot and inboard pad area for piston seal leaks. If there is a visible leak, the caliper must be replaced (they are not serviceable).
  4.  



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Fig. Fig. 15: Use the Special Tools (C-4171 and C-4689, or their equivalents) to install the new dust boot



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Fig. Fig. 16: After the bushings are installed into the caliper, install the Teflon® sleeves into the bushings

  1. Inspect the dust boot and the caliper pin bushings. Replace them if they are damaged, dry, or embrittled.
  2.  
  3. Clean the area around the dust boot with alcohol or a suitable solvent and wipe it dry. Remove the dust boot retainer with a finger or a blunt instrument and remove the dust boot from the caliper and piston grooves and discard it.
  4.  
  5. Clean the grooves in the piston and caliper and then coat a new boot with clean brake fluid, leaving a heavy coating inside. Position the boot over the piston and into the grooves of both piston and caliper. Install a boot retainer over the groove in the caliper.
  6.  
  7. Pry the bushings from the caliper with a small, dull tool. Discard the bushings and Teflon® sleeves.
  8.  
  9. Remove the Teflon® sleeves from new bushings. Install the bushings by putting pressure on their flanges with the fingers to press them in until seated. Reinstall the Teflon® sleeves.
  10.  
  11. Install the caliper as described above. Connect the brake hose, torquing the banjo bolt to 1929 ft. lbs.
  12.  
  13. Bleed the brake system. 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.
  14.  

 
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