Chrysler Full-Size Trucks 1989-1996 Repair Guide

Brake Caliper

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CAUTION
Brake pads 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.

REMOVAL & INSTALLATION



Dakota Models

See Figures 1, 2, 3, 4, 5 and 6

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  



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Fig. Fig. 1: Brake caliper mounting points-Dakota models



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Fig. Fig. 2: Lubricate the slide surfaces shown-Dakota models

  1. 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.
  2.  
  3. Plug the brake line to prevent loss of fluid.
  4.  



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Fig. Fig. 3: Be sure to correctly seat the brake shoes against the adapter ledge-Dakota models

  1. Remove the caliper slide pins.
  2.  
  3. Remove the caliper and brake pads from the rotor adapter.
  4.  



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Fig. Fig. 4: Exploded view of the Dakota disc brake components

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: Exploded view of the disc brake caliper components-2WD Dakota models

  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. Align the caliper and start the pins in by hand.
  2.  
  3. Tighten the pins to 22 ft. lbs. (30 Nm).
  4.  
  5. Connect the brake hose to the caliper. Use new washers to attach the hose fitting if the original washers are scored, worn or damaged.
  6.  



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Fig. Fig. 6: Exploded view of the disc brake caliper components-4WD Dakota models

  1. Fill and bleed the brake system.
  2.  
  3. Install the wheels.
  4.  
  5. Lower the vehicle.
  6.  

Chrysler Sliding Caliper

See Figures 7, 8, 9, 10, 11, 12, 13, 14, 15 and 16

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  



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Fig. Fig. 7: Details of the Chrysler sliding caliper

  1. 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.
  2.  



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Fig. Fig. 8: If a tighter fit is necessary, bend the outboard pad retaining fingers as shown

  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.  



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Fig. Fig. 9: Use a C-clamp to attach the shoe to the caliper fingers-Chrysler caliper



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Fig. Fig. 10: Rear view of the Chrysler sliding caliper assembly-4WD models shown

  1. Carefully slide the caliper out and away from the disc. Check the pads to be sure that they are reinstalled in the same position.
  2.  



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Fig. Fig. 11: Once unbolted, remove the caliper from the rotor



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Fig. Fig. 12: Pry the outboard shoe away from the Chrysler caliper fingers



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Fig. Fig. 13: Pivot the inboard shoe away from the adaptor

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. 14: View of the caliper flange and outboard shoe retainer flange-4WD models with Chrysler caliper

  1. Install the inboard shoe.
  2.  



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Fig. Fig. 15: Use two wrenches to disconnect the banjo bolt from the caliper brake line fittings



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Fig. Fig. 16: Be sure to keep track of the hardware as you remove the caliper

  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. (22 Nm).
  2.  

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

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

Bendix Sliding Caliper

  1. Support the front end on jackstands. Remove the wheel and tire.
  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 screwdriver to hold the caliper against the support assembly. 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).
  2.  
  3. Bleed the system of air. Replace the wheel and tire and lower the truck to the floor.
  4.  

Delco Sliding Caliper

See Figures 17, 18, 19 and 20

The 1994-96 Dakota and Pick-up models use the Delco sliding caliper.

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  



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Fig. Fig. 17: Front view of the Delco sliding caliper-1994-96 models



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Fig. Fig. 18: Remove/install the caliper once the slide pins are unbolted-1994-96 models

  1. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  2.  
  3. Remove the caliper mounting bolts with a 3 / 8 in. hex wrench or socket.
  4.  
  5. Loosen the bolt that secures the front brake hose fitting bolt in the caliper.
  6.  
  7. Rotate the caliper rearward off the rotor and out from its mount.
  8.  



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Fig. Fig. 19: Mounting bolt lubrication points-1994-96 Pick-up light duty caliper



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Fig. Fig. 20: Mounting bolt lubrication points-1994-96 Pick-up heavy duty caliper

  1. Remove the front brake hose fitting bolt completely, then remove the caliper with the pads installed as an assembly. Take care not to drip fluid onto the pad surfaces.
  2.  


WARNING
DO NOT depress the brake pedal with the caliper removed!

  1. Cover the open end of the front brake hose fitting to prevent dirt entry.
  2.  

To install:
  1. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease, or equivalent.
  2.  
  3. Lubricate the caliper mounting bolts, collars, bushings and bores with Dow 111®, or GE 661® silicone grease, or equivalent. (Please refer to illustrations).
  4.  
  5. Install the caliper over the rotor and seat it flush in its original position.
  6.  
  7. Install the mounting bolts by hand, then tighten them to 38 ft. lbs. (51 Nm).
  8.  
  9. Install the wheels.
  10.  
  11. Lower the vehicle.
  12.  
  13. Pump the brakes several times to seat the pads.
  14.  

OVERHAUL



Chrysler Sliding Caliper

See Figures 21, 22, 23, 24, 25 and 26

  1. Remove the caliper from the rotor.
  2.  



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Fig. Fig. 21: Place shop towels over the piston to absorb brake fluid which is expelled

  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.  



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Fig. Fig. 22: As your assistant presses the brake pedal, the caliper piston will will work its way out of the bore

  1. Carefully depress the brake pedal to hydraulically push the piston from its bore. Prop the pedal at any position below the first 1 in. (25mm) of travel to prevent further loss of fluid.
  2.  



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Fig. Fig. 23: Remove the piston for inspection and/or replacement

  1. Disconnect the plug and brake line after the first piston is removed.
  2.  



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Fig. Fig. 24: Remove the outer seal from the caliper piston bore

  1. Mount the caliper in a vise equipped with soft jaws.
  2.  
  3. Remove the dust boot.
  4.  



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Fig. Fig. 25: Pry out the inner seal from the caliper piston bore

  1. Using a small wooden of plastic pointed tool, work the piston seal out of its groove in the piston bore.
  2.  
  3. Clean all parts in alcohol and allow to air dry.
  4.  



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Fig. Fig. 26: Seat the seal using a suitable seal driver

  1. 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.
  2.  
  3. Coat a new piston boot with lubricant and leave a generous amount inside the boot.
  4.  
  5. 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.
  6.  
  7. 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.
  8.  
  9. Remove the plug and carefully push the piston down until it bottom.
  10.  
  11. Install the caliper on the vehicle, using the reverse order of removal.
  12.  
  13. Be sure to install the inboard pad anti-rattle spring on top of the retainer spring plate. Bleed the brakes. Road test the truck making several tops to wear any foreign material off of the pads.
  14.  

Bendix Sliding Caliper

  1. Clean the outside of the caliper in alcohol after removing it from the vehicle and removing the brake pads.
  2.  
  3. Drain the caliper through the inlet port.
  4.  
  5. Roll some thick shop cloths or rags and place them between the piston and the outer legs of the caliper.
  6.  
  7. Apply compressed air to the caliper inlet port until the piston comes out of the caliper bore. Use low air pressure to avoid having the piston pop out too rapidly and possible causing injury.
  8.  
  9. 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. Reapply the air pressure.
  10.  
  11. Remove the boot from the piston and seal from the caliper cylinder bore.
  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.  
  17. Coat the outside of the piston and both of the beads of dust boot with clean brake fluid. Insert the piston through the dust boot until the boot is around the bottom (closed end) of the piston.
  18.  
  19. Hold the piston and dust boot directly above the caliper cylinder bore, and use your fingers to work the bead of dust boot into the groove near the top of the cylinder bore.
  20.  
  21. 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 large C-clamp with a block of wood inserted between the clamp and the piston to bottom the piston, if necessary.
  22.  
  23. Install the brake pads and install the caliper. Bleed the brake hydraulic system and recenter the pressure differential valve. Do not drive the vehicle until a firm brake pedal is obtained.
  24.  

Delco Sliding Caliper

  1. Drain the brake fluid from the caliper.
  2.  
  3. Remove the brake pads.
  4.  
  5. Use a one inch thick layer of shop towels to cushion the piston for removal from its bore.
  6.  
  7. Use several short bursts of low pressure air to remove the piston from the bore.
  8.  
  9. Use a suitable prytool to remove the dust boot, then discard the boot.
  10.  
  11. Remove all seals, mounting bolts and bushings. Discard the original seal. Replace other components as necessary.
  12.  
  13. Clean the outside of the caliper in alcohol after removing it from the vehicle and removing the brake pads.
  14.  
  15. Drain the caliper through the inlet port.
  16.  
  17. Inspect the condition of the piston bore. If necessary, use a fiber brush to clean it.
  18.  
  19. If necessary, use a crocus cloth to lightly clean the bore, but use no other abrasive material.
  20.  
  21. Inspect the piston carefully. It must be free of rust, corrosion and pits. If any of these wear signs are evident, replace the piston. Do not attempt to "clean up'' the piston with an abrasive. This will only remove the special coating from the piston applied during manufacture.
  22.  
  23. Inspect the condition of the threads to the inlet and bleed screws. Repair damaged threads as necessary.
  24.  
  25. Check the bushings in the caliper bolt bores. replace if they are worn, cut or torn.
  26.  
  27. Make sure the work area is clean and dry.
  28.  
  29. Lubricate all components of the caliper with fresh brake fluid.
  30.  
  31. Install a new dust boot on the piston as follows:
    1. Lightly lubricate the lip of the new boot with Dow® or GE® silicone grease, or equivalent. Then work the boot lip into the boot groove at the top of the piston.
    2.  
    3. Stretch the boot rearward to straighten the boot folds, then move the bot forward until it snaps into place.
    4.  

  32.  
  33. Install a new seal on the piston. Slide the seal onto the piston and seat in the groove.
  34.  
  35. Install the piston. Apply more brake fluid to the piston, seal and bore. Then work the piston into the bore. Once the seal is properly seated, press the piston 3 / 4 of the way to the bottom of the bore by hand or with a hammer handle.
  36.  
  37. Seat the dust boot in the caliper with a suitable installer tool.
  38.  
  39. Finish pressing the piston to the bottom of the bore after the dust boot is seated.
  40.  

 
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