Chrysler RAM50/D50/Arrow 1979-1993 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



1979-86 Models

See Figures 1 through 10

  1. Raise and safely support the front of the vehicle on jackstands. Set the parking brake and block the rear wheels.
  2.  
  3. Siphon a sufficient amount of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing when removing or installing the caliper. This is necessary as the piston must be forced into the cylinder bore to provide clearance to install the caliper.
  4.  
  5. Remove the wheel.
  6.  

Disassemble brakes one wheel at a time. This will prevent parts confusion and also prevent the opposite piston from popping out during installation.

  1. Disconnect the brake hose.
  2.  
  3. Remove the caliper assembly from the steering knuckle.
  4.  



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Fig. Fig. 1: When removing a caliper, you must first start by forcing the piston into the cylinder bore



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Fig. Fig. 2: Removing the brake line retaining bracket from the caliper



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Fig. Fig. 3: Remove the two mounting bolts retaining the caliper to the caliper bracket



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Fig. Fig. 4: Remove and place the pivot (mounting) bolts in a clean spot to keep them from getting contaminated by dirt



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Fig. Fig. 5: Disconnect and plug the brake line attached to the caliper



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Fig. Fig. 6: After disconnecting and plugging the brake line to the caliper, pull the caliper off of the rotor and brake bracket assembly



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Fig. Fig. 7: Remove the outer brake pad with the outer shim from the brake bracket



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Fig. Fig. 8: Once the pad is removed, the shim can be separated from the pad-note the positions of the shims



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Fig. Fig. 9: Do the same with the rear brake pad



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Fig. Fig. 10: Remove the brake pad upper and lower spring clips from the brake bracket

  1. When installing the caliper, tighten the caliper to the steering knuckle to 51-65 ft. lbs. (69-88 Nm).
  2.  
  3. Connect the fluid hose to the caliper and then to the hard line at the body. Tighten the tube flare nut to 10-13 ft. lbs. (13-17 Nm). Tighten the bleeder screw to 5-7 ft. lbs. (7-9 Nm) and make sure the hose is correctly routed and not kinked. Remember to install any clips or retainers holding the line.
  4.  
  5. Refill the master cylinder reservoir to the MAX line. Bleed the brake system. Keep a close eye on the reservoir, maintaining its level at least half during the bleeding. Since the caliper was emptied, a fair amount of brake fluid may need to be added.
  6.  
  7. Reinstall the wheel and lower the vehicle to the ground.
  8.  
  9. Check the level in the fluid reservoir and top it off as needed. Before driving the vehicle, start the engine and operate the brake pedal several times to check the feel and engagement point of the brakes.
  10.  

1987-93 Models

  1. Raise and safely support the front of the vehicle on jackstands. Set the parking brake and block the rear wheels.
  2.  
  3. Siphon a sufficient amount of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing when removing or installing the caliper. This is necessary as the piston must be forced into the cylinder bore to provide clearance to install the caliper.
  4.  
  5. Remove the wheel.
  6.  

Disassemble brakes one wheel at a time. This will prevent parts confusion and also prevent the opposite piston from popping out during installation.

  1. Disconnect the brake line at the clip on the strut and disconnect the hose union at the caliper. Use a pan to catch any spilled fluid and immediately plug the hose end.
  2.  
  3. Remove the two caliper mounting bolts and then remove the caliper from the mounting bracket. Alternatively, remove the two bolts (screwed directly into the backing plate) which fasten the caliper support to the backing plate, and remove the entire assembly. Remove the brake pads and clips from the support as described above. Remove the lockpin (lower) and guide pin (upper) from the caliper support, and remove the caliper from the support.
  4.  

To install:
  1. Use a caliper compressor, a C-clamp or a large pair of pliers to slowly press the caliper piston back into the caliper.
  2.  
  3. If the mounting plate was removed from the backing plate, reinstall it and coat the bolts with an anti-seize compound. Tighten the bolts to 66 ft. lbs. (90 Nm).
  4.  
  5. Install the pads onto the mount and install the caliper. Make sure the slide bushings and bolts are clean and properly lubricated. Do not use regular grease or spray lubricants; they cannot withstand the extreme heat generated by the brakes. On 1987-93 models, tighten the lower bolt to 23-30 ft. lbs. (32-42 Nm) and the upper bolt to 29-36 ft. lbs. (40-50 Nm).
  6.  
  7. On the 1979-86 models, tighten the caliper support-to-knuckle bolts on rear wheel drive; 51-65 ft. lbs. (69-88 Nm), and 4WD models; 58-72 ft. lbs. (79-98 Nm).
  8.  
  9. Connect the fluid hose to the caliper and then to the hard line at the body. Tighten each fitting to 12 ft. lbs. (17 Nm) and make sure the hose is correctly routed and not kinked. Remember to install any clips or retainers holding the line.
  10.  
  11. Refill the master cylinder reservoir to the MAX line. Bleed the brake system. Keep a close eye on the reservoir, maintaining its level at least half during the bleeding. Since the caliper was emptied, a fair amount of brake fluid may need to be added.
  12.  
  13. Reinstall the wheel and lower the vehicle to the ground.
  14.  
  15. Check the level in the fluid reservoir and top it off as needed. Before driving the vehicle, start the engine and operate the brake pedal several times to check the feel and engagement point of the brakes.
  16.  

OVERHAUL



See Figures 11 through 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.  



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Fig. Fig. 11: Front disc brake caliper disassembly components


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: 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. 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



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Fig. Fig. 15: Use a prytool 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



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



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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



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

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  
  3. Remove the piston seals from the groove in the caliper bore.
  4.  
  5. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  6.  
  7. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  8.  
  9. Use crocus cloth to polish out light corrosion from the piston and bore.
  10.  
  11. Clean all parts with denatured alcohol and dry with compressed air.
  12.  

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.  
  11. Install the caliper in the vehicle.
  12.  
  13. Install the wheel and tire assembly, then carefully lower the vehicle.
  14.  
  15. Properly bleed the brake system.
  16.  

 
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