Chrysler Neon 1995-1999 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 surface 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 through 10

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. If you are removing the caliper for replacement or overhaul, disconnect the fluid line from the back of the caliper.
  6.  
  7. Unfasten the 2 brake caliper-to-steering knuckle guide pin bolts.
  8.  



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Fig. Fig. 1: The disc brake caliper is secured to the rotor with two mounting bolts (1) and has a brake fluid line (2) attached to the rear of it



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Fig. Fig. 2: Loosen the caliper mounting bolts ...



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Fig. Fig. 3: ... then pull the caliper mounting bolt from the bore

  1. Remove the caliper from the steering knuckle by firmly rotating the bottom end of the caliper away from the steering knuckle. Then, slide the opposite end of the caliper out from under the machined abutment on the steering knuckle.
  2.  



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Fig. Fig. 4: Rotate the bottom of the caliper away from the knuckle



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Fig. Fig. 5: ... then slide the upper end of the caliper out from under the abutment and remove it from the vehicle

  1. If you are not removing the caliper for replacement or overhaul, suspend the assembly with a suitable piece of wire from the strut. Do not allow the caliper to hang by the brake line!
  2.  



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Fig. Fig. 6: If necessary, you can remove the caliper sleeves



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Fig. Fig. 7: You should lubricate the caliper sleeves before installing them

To install:
  1. If you have installed new brake pads in the caliper, perform the following:
    1. Use a C-clamp or a pair of large pliers to retract the caliper piston back into the bore of the caliper.
    2.  

  2.  
  3. Apply a suitable multi-purpose lubricant to both steering knuckle abutments.
  4.  



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Fig. Fig. 8: Use a wire brush to clean off the steering knuckle abutments ...



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Fig. Fig. 9: ... then apply a layer of silicone lubricant to the abutments


WARNING
Be careful when installing the caliper onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.

  1. Carefully position the caliper assembly on the steering knuckle by first hooking the end of the caliper under the edge of the steering knuckle. Then, rotate the caliper into position on the steering knuckle.
  2.  
  3. Install the caliper guide pin bolts. Tighten the bolts to 12-15 ft. lbs.(18-20 Nm) for front calipers or to 16 ft. lbs. (22 Nm). Be very careful not to cross thread the caliper guide pin bolts.
  4.  
  5. If necessary, connect the brake line to the rear of the caliper and tighten the fitting to 35 ft. lbs. (48 Nm).
  6.  
  7. If the brake line was disconnected, bleed the brake system.
  8.  



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Fig. Fig. 10: Remove the rubber cap, (1) exposing the bleeder valve (2)

  1. Install the wheel and tire assembly, then carefully lower the vehicle.
  2.  


CAUTION
Before moving the vehicle, pump the brake pedal a few times to be sure the vehicle has a firm brake pedal.

  1. Take the vehicle for a test drive, making several stops to wear off any foreign material on the brakes and also, to properly seat the brake pads.
  2.  

OVERHAUL



See Figures 11 through 18

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.

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      Fig. Fig. 11: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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      Fig. Fig. 12: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  

  1. If equipped, remove the anti-rattle clip.
  2.  



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Fig. Fig. 13: On some vehicles, you must remove the anti-rattle clip

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



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Fig. Fig. 14: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 15: ... 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. 16: 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. 17: 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. 18: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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