Chrysler Full-Size Vans 1989-1998 Repair Guide

Brake Pads

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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 and 3

  1. Drain some of the fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle securely on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the caliper from the adapter.
  8.  
  9. Suspend the caliper with wire to avoid damage to the flexible brake hose.
  10.  
  11. Remove the outboard pad from the caliper by prying between the pad and the caliper fingers.
  12.  
  13. Remove the inboard pad from the caliper support by the same method.
  14.  

Do not depress the brake pedal with the pads removed.

  1. Push the caliper piston to the bottom of its bore. This may be done with a large C-clamp or a pair of large pliers by placing a flat metal bar against the piston and depressing the piston 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 adapter and tighten retaining bolts to 20 ft. lbs. (27 Nm).
  6.  
  7. Pump the brake pedal until it is firm.
  8.  
  9. Refill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 3 or DOT 4 specifications. As necessary, properly bleed the brake system.
  10.  

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

  1. Install the wheels and lower the vehicle.
  2.  
  3. Check the brake pedal for a firm feel. Road test the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Usually the outer pad will remain in the caliper when it is removed, while ...



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Fig. Fig. 2: ... the inner pad will remain in the mounting bracket



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Fig. Fig. 3: A suitable tool, like the one here from Lisle®, must be used to compress the piston into the caliper

INSPECTION



Inspect the brake pads for wear using a ruler or Vernier caliper. Compare measurements to the brake specifications chart. If the lining is thinner than specification on any part of the pad, or there is evidence of the lining being contaminated by brake fluid or oil, replace both brake pad assemblies (a complete axle set).

 
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