Chrysler Full-Size Vans 1967-1988 Repair Guide

Brake Caliper

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CAUTION
Brake shoes or 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.

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the Chrysler sliding caliper and related components

REMOVAL & INSTALLATION



  1. Raise and support the front end on 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.  
  7. Plug the brake line to prevent loss of fluid.
  8.  
  9. Remove the retaining screw, clip and antirattle spring that attach the caliper to the adaptor.
  10.  
  11. Carefully slide the caliper out and away from the disc. Check the pads to be sure that they are reinstalled in the same position.
  12.  

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.  
  3. Install the inboard shoe.
  4.  
  5. Slide the caliper into position on the adaptor and over the rotor.
  6.  


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

  1. Install the anti-rattle springs and retaining clips and torque the retaining screws to 16 ft. lbs.
  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.  

OVERHAUL



  1. Remove the caliper from the rotor.
  2.  
  3. 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.
  4.  
  5. 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.
  6.  
  7. Disconnect the plug and brake line after the first piston is removed.
  8.  
  9. Mount the caliper in a vise equipped with soft jaws.
  10.  
  11. Remove the dust boot.
  12.  
  13. Using a small wooden of plastic pointed tool, work the piston seal out of its groove in the piston bore.
  14.  
  15. Clean all parts in alcohol and allow to air dry.
  16.  
  17. 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.
  18.