Dodge Aspen/Volare 1976-1980 Repair Guide




Follow steps 1 through 6 of "Brake Pad Removal." Disconnect the brake line at the body, not the caliper, and remove the caliper. Installation is the reverse of removal. Bleed the brakes.


  1. Remove the caliper assembly from the car without disconnecting the hydraulic line.
  3. Support the caliper assembly on the upper control arm and surround it with shop towels to absorb any brake fluid. Slowly depress the brake pedal until the piston is pushed out of its bore.

Do not use compressed air to force the piston from its bore; injury could result.

  1. Disconnect the brake line from the caliper and plug it to prevent fluid loss.
  3. Mount the caliper in a soft-jawed vise and clamp lightly. Do not tighten the vise too much or the caliper will become distorted.
  5. Work the dust boot out with your fingers.
  7. Use a small pointed wooden or plastic stick to work the piston seal out of the groove in the bore. Discard the seal.

Using a screwdriver or other metal tool could scratch the piston bore.

  1. Using the same wooden or plastic stick, press the outer bushings out of the housing. Discard the old bushings. Remove the inner bushings in the same manner. Discard them as well.
  3. Clean all parts in denatured alcohol or brake fluid. Blow out all bores and passages with compressed air.
  5. Inspect the piston and bore for scoring or pitting. Replace the piston if necessary. Bores with light scratches or corrosion may be cleaned with crocus cloth. Bores with deep scratches may be honed if you do not increase the bore diameter more than 0.002 in. Replace the housing if the bore must be enlarged beyond this.

Black stains are caused by piston seals and are harmless.

  1. If the bore had to be honed, clean its grooves with a stiff, non-metallic rotary brush. Clean the bore twice by flushing it out with brake fluid and drying it with a soft, lint-free cloth.

To install:

  1. Clamp the caliper in a soft-jawed vise; do not overtighten.
  3. Dip a new piston seal in brake fluid or the lubricant supplied with the rebuilding kit. Position the new seal in one area of its groove and gently work it into place with clean fingers, so that it is correctly seated. Do not use an old seal.
  5. Coat a new boot with brake fluid or lubricant (as above), leaving a generous amount inside.
  7. Insert the boot in the caliper and work it into the groove, using your fingers only. The boot will snap into place once it is correctly positioned. Run your forefinger around the inside of the boot to make sure that it is correctly seated.
  9. Install the bleed screw in its hole and plug the fluid inlet on the caliper.
  11. Coat the piston with brake fluid or lubricant. Spread the boot with your fingers and work the piston into the boot.
  13. Depress the piston; this will force the boot into its groove on the piston. Remove the plug and bottom the piston in the bore.
  15. Compress the flanges of new guide pin bushings and work them into place by pressing in on the bushings with your fingertips, until they are seated. Make sure that the flanges cover the housing evenly on all sides.
  17. Install the caliper on the car as previously outlined.