Chrysler Full-Size Trucks 1967-1988 Repair Guide

Disc Brake Calipers

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CAUTION
Brake shoes 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.

REMOVAL & INSTALLATION



See Figures 1 through 7

Chrysler Sliding Caliper
  1. Loosen the lug nuts slightly before you jack up the front of the truck and support it with jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the rubber brake hose from the tubing at the frame mount. If the pistons are to be removed from the caliper, leave the brake hose connected to the caliper. Check the rubber hose for cracks or chafed spots.
  6.  



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Fig. Fig. 1: Remove the hose connected to the caliper

  1. Plug the brake line to prevent loss of fluid.
  2.  
  3. Remove the retaining screw, clip and anti-rattle spring that attach the caliper to the adaptor.
  4.  
  5. Carefully slide the caliper out and away from the disc. Check the pads to be sure that they are reinstalled in the same position.
  6.  



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Fig. Fig. 2: Rear view of the single piston Chrysler sliding caliper-2WD trucks



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Fig. Fig. 3: Front view of the single piston Chrysler sliding caliper-2WD trucks



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Fig. Fig. 4: Removing the caliper on 2WD trucks

To install:
  1. Position the outboard shoe in the caliper. The shoe should not rattle in the caliper. If it does, or if any movement is obvious, bend the shoe tabs over the caliper to tighten the fit.
  2.  



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Fig. Fig. 5: Outboard shoe removal-4WD trucks

  1. Install the inboard shoe.
  2.  



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Fig. Fig. 6: Inboard shoe removal-4WD trucks

  1. Slide the caliper into position on the adaptor and over the rotor.
  2.  


WARNING
Take great care to avoid dislodging the piston dust boot!

  1. Install the anti-rattle springs and retaining clips and tighten the retaining screws to 16 ft. lbs. (21 Nm).
  2.  

The inboard shoe must always be installed on top of the retainer spring plate.

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Fig. Fig. 7: Inboard shoe removal-2WD trucks

  1. Fill the system with fresh fluid and bleed the brakes.
  2.  
  3. Lower the truck.
  4.  

Bendix Sliding Caliper
  1. Loosen the lug nuts slightly before you jack up the front of the truck and support it with jackstands. Remove the front wheel.
  2.  
  3. Disconnect the brake hose. Cap the hose and plug the caliper.
  4.  
  5. Remove the key retaining screw and drive the key out with a brass drift.
  6.  
  7. Rotate the key end of the caliper out and slide the other end out.
  8.  
  9. Thoroughly clean the sliding areas.
  10.  

To install:
  1. Position the caliper rail into the slide on the support and rotate the caliper onto the rotor. Start the key and spring by hand. The spring should be between the key and caliper and the spring ends should overlap the key. If necessary, use a prytool to hold the caliper against the support assembly.
  2.  
  3. Drive the key and spring into position, aligning the correct notch with the hole in the support. Install the key retaining screw and tighten to 12-20 ft. lbs. (16-27 Nm).
  4.  
  5. Bleed the system of air. Replace the wheel and tire and lower the truck to the floor.
  6.  

Chrysler Floating Caliper
  1. Raise the vehicle and remove the wheel.
  2.  
  3. Remove guide pins, positioners, and anti-rattle spring.
  4.  
  5. Slowly slide caliper assembly out and away from rotor.
  6.  
  7. Disconnect the brake hose.
  8.  
  9. Inspect for any corrosion on mating surfaces of the caliper and anchor plate.
  10.  

To install:
  1. Install the caliper with new guide pin bushings, the flanged end faces towards the outside of vehicle.
  2.  
  3. Carefully slide the caliper assembly into position over rotor.
  4.  
  5. Install new positioners over guide pins with open ends towards outside and stamped arrows pointing up.
  6.  
  7. Align guide pin holes in caliper and anchor plate, install guide pin assemblies.
  8.  
  9. Bleed the brake system.
  10.  
  11. Install the wheel, lower the vehicle and tighten lug nuts.
  12.  

OVERHAUL



Chrysler Sliding Caliper

See Figures 8 through 13

  1. Remove the caliper from the rotor.
  2.  



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Fig. Fig. 8: Rear view of a mounted 4WD caliper

  1. If the pistons are to be removed, support the caliper on the upper control arm and surround it with towels to absorb the hydraulic fluid that will be lost.
  2.  
  3. Carefully depress the brake pedal to hydraulically push the piston from its bore. Prop the pedal at any position below the first inch of travel to prevent further loss of fluid.
  4.  
  5. Disconnect and plug the brake line after the first piston is removed.
  6.  



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Fig. Fig. 9: Use hydraulic pressure from the system to push out the piston and remove it from the bore ...



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Fig. Fig. 10: ... then disconnect the brake hose

  1. Carefully mount the caliper in a vise. DO NOT clamp tightly of the caliper or it may be damaged. It is best to use a soft-jawed vise or to use blocks of wood to help protect the caliper.
  2.  



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Fig. Fig. 11: The boot may seem larger than the groove diameter, but once it is aligned, it will snap right in

  1. Remove the dust boot.
  2.  
  3. Using a small wooden of plastic pointed tool, work the piston seal out of its groove in the piston bore.
  4.  



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Fig. Fig. 12: Be VERY careful when removing the piston seal-DO NOT score the piston bore

  1. Clean all parts in alcohol and allow to air dry.
  2.  
  3. Dip a new piston seal in the lubricant supplied with the factory rebuilding kit or in clean brake fluid. Install the seal in the groove in the bore.
  4.  
  5. Coat a new piston boot with lubricant and leave a generous amount inside the boot.
  6.  



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Fig. Fig. 13: Always use a new seal kit for reassembly, as you can see the old seals are not usable

  1. Install the piston seal into the caliper by working it into the groove with your fingers only. At first sight, the seal will appear larger than the bore, but will snap into place when properly seated.
  2.  
  3. Plug the high pressure inlet to the caliper and the bleeder screw hole and coat the piston with lubricant. Spread the boot with your fingers and work the piston into the boot, pressing down evenly.
  4.  
  5. Remove the plug and carefully push the piston down until it bottoms.
  6.  
  7. Install the caliper on the vehicle.
  8.  
  9. Be sure to install the inboard pad anti-rattle spring on top of the retainer spring plate.
  10.  
  11. Bleed the brakes. Road test the truck making several stops to wear any foreign material off the pads.
  12.  

Bendix Sliding Caliper

See Figures 14, 15 and 16

  1. Remove the caliper from the truck, remove the pads, and clean the outside of the caliper in alcohol.
  2.  



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Fig. Fig. 14: Exploded view of the caliper assembly

  1. Drain the caliper through the inlet port.
  2.  
  3. Roll some thick shop cloths or rags and place them between the piston and the outer legs of the caliper.
  4.  
  5. Apply compressed air to the caliper inlet port until the piston comes out of the caliper bore. Use a LOW air pressure to avoid having the piston pop out too quickly and possibly causing injury.
  6.  
  7. If the piston becomes cocked in the cylinder bore and will not come out, remove the air pressure and tap the piston with a soft hammer to try and straighten it. Do not use a sharp tool or pry the piston out of the bore. Re-apply the air pressure.
  8.  
  9. Using a small pointed wooden or plastic rod, carefully remove the piston seal from the caliper bore. Do not use a metal tool of any kind for this portion of the job, it will result in damage to the cylinder bore or the seal groove.
  10.  
  11. Discard of the seal and boot.
  12.  
  13. Clean the piston and caliper in alcohol.
  14.  
  15. Lubricate the piston seal with clean brake fluid, and position the seal in the groove in the cylinder bore.
  16.  



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Fig. Fig. 15: Be sure to lube the piston seal with fresh brake fluid before inserting it in the caliper

  1. Coat the outside of the piston and both of the dust boot beads with clean brake fluid. Insert the piston through the dust boot until the boot is around the bottom (closed end) of the piston.
  2.  
  3. Hold the piston and dust boot directly above the caliper cylinder bore, and use your fingers to work the dust boot bead into the groove near the top of the cylinder bore. The boot may seem larger than the diameter of the groove, but once in proper place, it will snap right in.
  4.  



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Fig. Fig. 16: The boot may seem larger than the groove diameter, but once it is aligned, it will snap right in

  1. After the bead is seated in the groove, press straight down on the piston until it bottoms in the bore. Be careful not to cock the piston in the bore. Be careful not to cock the piston in the bore. Use a C-clamp with a block of wood inserted between the clamp and the piston to bottom the piston, if necessary.
  2.  
  3. Install the brake pads and install the caliper. Bleed the brake hydraulic system and recenter the pressure differential valve. Do not drive the truck until a firm brake pedal is obtained.
  4.  

Chrysler Floating Caliper
  1. With the caliper removed from the truck, remove the dust boot.
  2.  
  3. Using a suitable tool, remove the piston from caliper.
  4.  
  5. Using a small wooden or plastic rod, work the piston seal out of its groove in the piston bore and discard seal. Remove the bleeder screw.
  6.  
  7. Clean all parts with alcohol or other suitable solvent and blow dry with compressed air.
  8.  
  9. Check the piston and bore for scoring and pitting.
  10.  
  11. Dip the piston seal, dust boot, and piston in suitable lubricant. Work the seal into the groove in the piston bore until it is firmly seated.
  12.  
  13. Install the dust boot into the outer groove of the cylinder bore.
  14.  

Boot will snap into place when properly positioned.

  1. Insert the piston into the bore, then press against the piston until the boot is forced into the groove around the piston.
  2.  
  3. Remove the plugs and bottom the piston into bore.
  4.  
  5. Install the brake pads and install the caliper. Bleed the brake hydraulic system and recenter the pressure differential valve. Do not drive the truck until a firm brake pedal is obtained.
  6.  

 
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