Chrysler Full-Size Vans 1967-1988 Repair Guide

Brake Pads

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INSPECTION



Remove the brake pads as described below and measure the thickness of the lining. If the lining at any point on the pad assembly is less 0.0625" ( 1 / 16 "; 1.5mm) for LD brakes or 0.03125" ( 1 / 32 "; 0.794mm) for HD brakes, thick (above the backing plate or rivets), or there is evidence of the lining being contaminated by brake fluid or oil, replace the brake pad.


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



See Figures 1 through 8

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Fig. Fig. 1: Front disc brake components



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Fig. Fig. 2: Loosen the caliper retaining clip's mounting bolt ...



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Fig. Fig. 3: ... then remove the bolt/clip assembly



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Fig. Fig. 4: Slowly slide the caliper off of the rotor



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Fig. Fig. 5: It may be necessary to pry the outboard pad loose from the caliper



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Fig. Fig. 6: Remove the outboard pad from the caliper



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Fig. Fig. 7: Slide the inboard pad out of the caliper mount adaptor



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Fig. Fig. 8: Use a C-clamp on the inboard pad to press the caliper piston into the caliper housing

See Figure 9

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Fig. Fig. 9: The outboard pad should fit snugly on the caliper

See Figure 10

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Fig. Fig. 10: Bend the outboard shoe retaining flanges if the pad is loose in the caliper

See Figure 11

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Fig. Fig. 11: If the pad is too tight to install by hand, use a C-clamp to fully seat the outboard pad

Never replace the pads on one side only! Always replace pads on both wheels as a set!

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the caliper retaining clips and anti-rattle springs.
  6.  
  7. 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.
  8.  
  9. Drain some of the fluid from the master cylinder.
  10.  
  11. 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!
  12.  

To install:
  1. 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.
  2.  
  3. Slide the new pads into the caliper and caliper support. The ears of the pad should rest on the bridges of the caliper.
  4.  
  5. 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.
  6.  
  7. Check the fluid level in the master cylinder and add fluid as needed.
  8.  
  9. Install the wheels.
  10.  
  11. Road test the van. The van may pull to one side, but the pull should disappear shortly as the pads wear in.
  12.  

 
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