Crossfire, 2004-2005

Brake Caliper

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the rear tire and wheel assembly.
  6.  
  7. Drain a small amount of fluid from the master cylinder brake reservoir with a clean suction gun.
  8.  
  9. Remove or disconnect the following:
    WARNING
    DO NOT spill the brake fluid on any painted surfaces. Brake fluid can damage paint.



    Caliper mounting bolts
     
    Caliper from the knuckle
     



    Brake hose by rotating the caliper while holding the brake hose with a wrench
     
    Brake pads retaining pin by knocking out with a punch
     
    Anti-rattle clip and remove the brake pads from the caliper

    Click image to see an enlarged view

    Fig. Brake caliper (3), rotor (2) and hydraulic connections (1, 4)

     

  10.  

To install:

  1. Install or connect the following:
    WARNING
    Verify the brake hose is not twisted or kinked before installing the caliper to the knuckle.



    Rear brake pads
     
    Brake hose to caliper by holding the brake hose with a wrench and rotating caliper until snug and fully tighten the brake hose
     



    Caliper to the knuckle and tighten the bolts to 41 ft. lbs. (55 Nm)
     

  2.  
  3. Fill and bleed the brake system.
  4.  
  5. Install the wheel and tire assembly.
    CAUTION
    Do not move the vehicle until a firm brake pedal is obtained.

  6.  
  7. Lower the vehicle.
  8.  
  9. Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved.
  10.  
  11. Top off the brake fluid reservoir with new fluid if necessary, and check for leaks.
  12.  

 
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