Chrysler Full-Size Vans 1989-1998 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be 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 Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11



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Fig. Fig. 1: Disc brake caliper mounting components

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the rubber brake hose from the tubing at the frame mount. Check the rubber hose for cracks or chafed spots.
  6.  

If the piston is to be removed from the caliper, leave the brake 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 adapter.
  4.  
  5. Carefully slide the caliper out and away from the disc. A small prybar may be necessary to free the caliper from the adapter.
  6.  
  7. If the old brake pads are being used, matchmark them for installation reference.
  8.  

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. Lubricate the slide surfaces of the caliper with high temperature grease.
  6.  
  7. Slide the caliper into position on the adapter and over the rotor.
  8.  


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

  1. Install the anti-rattle springs and retaining clips and tighten the retainer bolts to 20 ft. lbs. (2 Nm).
  2.  
  3. Connect the rubber brake hose to the tubing at the frame mount and tighten to 10 ft. lbs. (47 Nm).
  4.  
  5. Refill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 3 or DOT 4 specifications.
  6.  
  7. Properly bleed the brake system.
  8.  
  9. Install the wheels.
  10.  

Failure to tighten the lug nuts to the proper torque in a star pattern may result in damage to the brake rotor.

  1. Lower the vehicle.
  2.  



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Fig. Fig. 2: Always use a line wrench when loosening brake line fittings



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Fig. Fig. 3: The front brake caliper hose-to-caliper junction



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Fig. Fig. 4: The front brake hose is attached to the caliper by a through-bolt



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Fig. Fig. 5: Disconnect the brake hose from the caliper



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Fig. Fig. 6: There is a washer on the brake hose fitting at the caliper. Be sure not to lose this, since the hose will leak if it is not installed



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Fig. Fig. 7: On some models, the calipers are secured by retaining clips



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Fig. Fig. 8: View of the caliper retaining clip, along with the anti-rattle spring and bolt



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Fig. Fig. 9: Slide the caliper off of the rotor



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Fig. Fig. 10: Thoroughly clean the caliper slides before assembly



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Fig. Fig. 11: Lubricate the caliper slides with the appropriate type of grease before installing the caliper

OVERHAUL



See Figures 12, 13, 14, 15, 16, 17, 18 and 19

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



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Fig. Fig. 12: For some types of calipers, use compressed air to drive the piston out of the caliper, but be sure to keep your fingers clear



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Fig. Fig. 13: Withdraw the piston from the caliper bore



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Fig. Fig. 14: On some vehicles, you must remove the anti-rattle clip

  1. Use a prybar to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 15: Use a prybar to carefully pry around the edge of the boot ...



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Fig. Fig. 16: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 17: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 18: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 19: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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