Chrysler Full-Size Trucks 1967-1988 Repair Guide

Disc Brake Pads

Print


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.

INSPECTION



Remove the brake pads as described later in this section and measure the thickness of the lining. If the lining at ANY point on the pad assembly is less then specification, or there is evidence of the lining having been contaminated by brake fluid or oil, replace the brake pad. For light duty brakes the lining should be at least 1 / 16 in. (1.5mm) thick above the backing plate or rivets (as applicable). Heavy duty brakes should allow a minimum lining thickness of 1 / 32 in. (0.8mm).

Of course, many states have their own standards for safety. When in doubt, check with local authorities or an official inspection station for local safety inspection standards.

REMOVAL & INSTALLATION



NEVER REPLACE THE PADS ON ONE SIDE ONLY! ALWAYS REPLACE PADS ON BOTH WHEELS AS A SET!

Chrysler Sliding Caliper

See Figures 1 through 10

  1. Raise and support the front end on jackstands.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Finger and shoe retainer flange locations

  1. Remove the wheels.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: The wheel must be removed for access to the front brake components

  1. Remove the caliper retaining clips and anti-rattle springs.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Loosen the retaining clip bolt with the proper size socket



Click image to see an enlarged view

Fig. Fig. 4: After loosening, unthread the bolt and place it where it will be easily found for installation

  1. Remove the caliper from the disc by slowly sliding the caliper and brake pad assembly out and away from the disc. Do not damage the flexible brake hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Carefully slide the caliper away

  1. Drain some of the fluid from the master cylinder.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Once the caliper is free of the rotor and mounting, the brake pads may be removed



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of a sliding caliper assembly

  1. Remove the outboard pad from the caliper by prying between the pad and the caliper fingers. Remove the inboard pad from the caliper support by the same method. DO NOT depress the brake pedal with the pads removed!
  2.  
  3. Push the pistons to the bottom of their bores. This may be done with a large C-clamp or a pair of large pliers by placing a flat metal bar against the pistons and depressing the pistons with a steady force. This operation will displace some of the fluid in the master cylinder.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Attaching the shoe to the caliper fingers with a C-clamp

  1. Slide the new pads into the caliper and caliper support. The ears of the pad should rest on the bridges of the caliper.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Bending the outboard shoe retainer flange

  1. Install the caliper on the disc and install the caliper retaining clips, pins and anti-rattle springs. Pump the brake pedal until it is firm.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Install the retaining clip with the pads and caliper in position-now where did you put the bolt-

  1. Check the fluid level in the master cylinder and add fluid as needed.
  2.  
  3. Install the wheels.
  4.  
  5. Road test the truck. Although the vehicle may pull to one slightly, the pull should disappear shortly as the pads wear in.
  6.  

Bendix Sliding Caliper

See Figures 11 through 19

  1. Remove and discard some of the fluid from the master cylinder without contaminating the contents to avoid overflow later on.
  2.  
  3. Support the vehicle on jackstands. Remove the wheels.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Bendix caliper adapter, steering knuckle adaptor



Click image to see an enlarged view

Fig. Fig. 12: Before removing the caliper, use a C-clamp to carefully bottom the piston in its bore

  1. Put an 8 in. (203mm) C-clamp over the caliper and use it to push the outer pad in and pull the caliper out. This bottoms the caliper piston in its bore.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Use a C-clamp to carefully bottom the piston

  1. Remove the key retaining screw. Drive the caliper support key and spring out toward the outside, using a brass drift.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Use a hammer and brass drift to tap out the support key and spring



Click image to see an enlarged view

Fig. Fig. 15: Bendix front disc unit

  1. Push the caliper down and rotate the upper end up and out. Support the caliper, so as not to damage the brake hose.
  2.  
  3. Remove the outer pad from the caliper. You may have to tap it to loosen it. Remove the inner pad, removing the anti-rattle clip from the lower end of the shoe.
  4.  



Click image to see an enlarged view

Fig. Fig. 16: Removal of the inner pad from the adapter

To install:
  1. Thoroughly clean the sliding contact areas on the caliper and spindle assembly.
  2.  
  3. Put the new anti-rattle clip on the lower end of the new inner pad. Put the pad and clip in the pad abutment with the clip tab against the abutment and the loop-type spring away from the disc. Compress the clip and slide the upper end of the pad into place.
  4.  
  5. If the caliper piston isn't bottomed, bottom it with a C-clamp.
  6.  
  7. The replacement outer pad may differ slightly from the original equipment. Put the outer pad in place and press the tabs into place with your fingers. You can press the tabs in with a C-clamp, but be careful of the lining.
  8.  



Click image to see an enlarged view

Fig. Fig. 17: Press the outboard pad onto the caliper, but make sure you protect the pad with a wooden block

  1. Position the caliper on the spindle assembly by pivoting it around the upper mounting surface. Be careful of the boot.
  2.  
  3. Use a prytool to hold the upper machined surface of the caliper against the support assembly. Drive a new key and spring assembly into place with a plastic mallet. Install the retaining screw and tighten to 12-20 ft. lbs. (16-27 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 18: Install the caliper over the disc into the upper mating groove



Click image to see an enlarged view

Fig. Fig. 19: Install the key and spring on the caliper

  1. Replace the wheels and tires and lower the truck to the floor. Fill the master cylinder as specified in General Information & Maintenance . Depress the brake pedal firmly several times to seat the pads on the disc. Don't drive until you get a firm pedal.
  2.  

Chrysler Floating Caliper
  1. Raise the vehicle and remove the wheel.
  2.  
  3. Remove the guide pins, positioners, and anti-rattle spring.
  4.  
  5. Slowly slide the caliper assembly away from the rotor.
  6.  

Support the caliper to prevent damage to brake hose.

  1. Remove the disc pads, guide pin bushings, and positioners, discard of the bushings and positioners.
  2.  

To install:
  1. Check the piston seal for leaks and inspect the dust boot for damage.
  2.  
  3. Inspect the piston for damage or corrosion.
  4.  
  5. Check for corrosion or rust on the mating surfaces of the caliper and anchor plate.
  6.  
  7. Install new guide pin bushings with flanged end toward outside of vehicle.
  8.  
  9. Bottom piston into cylinder bore and install pads.
  10.  

Be sure the metal portion of pad is fully seated in recess of caliper and anchor plate.

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

 
label.common.footer.alt.autozoneLogo