Dodge Colt/Challenger/Conquest/Vista 1971-1989 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



1971 to Mid-1973 Models
  1. Block the rear wheel, loosen the wheel lugs and raise front of the car. Support safely on jackstands and remove the wheel.
  2.  
  3. Disconnect the brake line from the brake hose. Remove the union bolt of the flexible hose which is connected to caliper.
  4.  
  5. Remove the cross-spring. Remove the clips and the retaining pins.
  6.  
  7. Using a pair of locking pliers, remove both brake pads and shims. Mark them left and right, if they are being reused.
  8.  
  9. Unscrew the two retaining bolts from the bracket behind the disc and remove the caliper.
  10.  

To install:

  1. Install the caliper on the bracket and tighten the bolts to 29-36 ft. lbs.
  2.  
  3. Connect the brake line to the caliper.
  4.  
  5. Install the pads and shims following the procedure given previously.
  6.  
  7. Bleed the brakes.
  8.  
  9. Install the wheel and lower the car.
  10.  

1973-83 Station Wagon and Challenger

A sliding caliper type disc brake is used on station wagons and Challengers.

  1. Loosen the wheel lugs, block the rear wheels, raise the front of the car and support on jackstands. Remove the wheels.
  2.  
  3. Remove approximately half of the brake fluid from the master cylinder.
  4.  
  5. Disconnect the brake line at the caliper. Remove the spring pin(s) and pull the stopper plug(s) from the end of the caliper.
  6.  
  7. Move the caliper back and forth to loosen, then remove the caliper from the support.
  8.  

To install:

  1. Seat the caliper over the mounting bracket (caliper piston seated in bore). Install the caliper stopper plug and the spring pin.
  2.  
  3. Connect the brake line, fill the master cylinder and bleed the brake system.
  4.  
  5. Install the tire and wheel, lower the car to the ground and road test.
  6.  

Mid-1973-83 Rear Wheel Drive
  1. Remove the disc brake pad.
  2.  
  3. Remove the brake hose clip from the strut area, then disconnect the brake hose from the caliper.
  4.  
  5. Remove the caliper assembly by removing torque plate and adapter mounting bolts.
  6.  

To install:

  1. When installing the caliper assembly, observe the following instructions after referring to Disc Brake Pads.
  2.  
  3. Tighten the caliper assembly (torque plate) to the adapter to 51-66 ft. lbs.
  4.  
  5. After tightening the brake hose to 9-12 ft. lbs., bleed the brake hydraulic system.
  6.  

Since the wheel cylinder uses a large piston, even the presence of a small amount of air, will have a great effect on the brake pedal stroke. Bleeding, therefore, should be performed carefully and thoroughly.

1979-84 Front Wheel Drive Without Turbo


Click image to see an enlarged view

Fig. Fig. 1 Piston and seal used on front wheel drive non Turbo 1979-84 models



Click image to see an enlarged view

Fig. Fig. 2 Apply grease to these spots when installing the brake caliper components



Click image to see an enlarged view

Fig. Fig. 3 When replacing the caliper components, inspect any seals and bushings/boots for deterioration

  1. Remove the brake pads.
  2.  
  3. Remove the brake hose from the clip on the strut.
  4.  
  5. Disconnect the hose from the caliper.
  6.  
  7. Remove the torque plate and adapter housing bolts and lift off the caliper.
  8.  

To install:

  1. Install the caliper and install the torque plate/adapter mounting bolts. Torque the bolts to 43-58 ft. lbs. Connect the brake hose and install the brake pads. Bleed the system and road test the car.
  2.  

1984-89 Colt Turbo, 1985-89 Colt Without Turbo and Vista
  1. Disconnect the brake hose from the clip at the strut.
  2.  
  3. Remove the pads.
  4.  

On late models equipped with the PFS15 type front disc brakes; the caliper and pads are retained to the adapter by two sleeve pin bolts. Remove the pin bolts and service the assembly as required. Sleeve bolt torque is 16-23 ft. lbs.

  1. Remove the upper pin bolt.
  2.  
  3. Lift off the caliper.
  4.  
  5. Clean all parts thoroughly.
  6.  
  7. Place the caliper into position and install the pin bolt. Torque the pin bolts to 16-23 ft. lbs. Bleed the system. Road test the car.
  8.  

Conquest
  1. Remove the front pads, as described above.
  2.  
  3. Remove the slider pin(s).
  4.  
  5. Loosen the brake hose at the caliper.
  6.  
  7. Lift off the caliper and unscrew the hose.
  8.  
  9. Install the caliper and brake pads. Connect the brake hose. Torque the pins to 70 ft. lbs. Check the brake dragging force as described under Pad Removal and Installation.
  10.  

OVERHAUL



1971-Mid-1973 Models


Click image to see an enlarged view

Fig. Fig. 4 With the caliper off the vehicle, remove the retaining ring and seal



Click image to see an enlarged view

Fig. Fig. 5 Removing the inner piston with a drift

  1. Remove the caliper as previously outlined. Remove the retaining ring and seal from the outer piston.
  2.  
  3. While holding the piston with a piece of hardwood, apply air pressure through the brake line fitting and force the outer piston from the caliper.
  4.  


CAUTION
If the piston on the other side isn't held, both pistons could pop out simultaneously, causing possible injury.

  1. Remove the inner piston by inserting a drift through the union bolt opening and tapping it out.
  2.  
  3. Remove the piston seals, being careful not to damage the cylinder seal grooves.
  4.  
  5. Clean all the removed parts in brake fluid.
  6.  
  7. Replace worn, damaged, or corroded cylinders and pistons.
  8.  
  9. Replace rubber parts as a matter of course during caliper disassembly.
  10.  
  11. Apply silicone grease to the surfaces of the piston seal and the inner side of the dust seal.
  12.  
  13. Lubricate the cylinder walls and the outer side of the piston, insert the piston into the cylinder without twisting it. Install the dust seal and the retaining ring.
  14.  
  15. Repeat the assembly operation for the second piston. Install the caliper as previously outlined.
  16.  

Mid 1973-83 Rear Wheel Drive Except Wagon and Challenger
  1. Loosen and remove the caliper half retaining bolt.
  2.  
  3. Separate the two caliper halves.
  4.  
  5. Remove the dust seal, and then remove the piston by applying compressed air to the hose fitting.
  6.  


CAUTION
Be careful that the piston doesn't fly out and cause injury.

  1. Carefully remove the piston seal, so as not to damage the cylinder.
  2.  
  3. Clean all parts in denatured alcohol.
  4.  
  5. Inspect the piston and cylinder for scoring or corrosion. Replace any defective parts.
  6.  
  7. Assemble the caliper using the new parts supplied in the rebuilding kit.
  8.  
  9. Apply brake fluid to the piston before assembly. Insert the piston seal into the piston carefully so that the seal isn't twisted.
  10.  
  11. Whenever the torque plate has been removed from the inner caliper half, it is necessary to clean the torque plate shaft and the shaft bore of the caliper and apply brake assembly grease to the rubber bushing, wiper seal inner surface, and torque plate shaft before assembly.
  12.  
  13. Tighten the caliper bridge bolts to 58-59 ft. lbs.
  14.  

1973-83 Wagon and Challenger
  1. Remove the caliper as outlined in the following section.
  2.  
  3. Remove the caliper piston dust boot. Cover the piston with a rag and piece of hardwood. While holding the wood, inject air pressure into the brake hose fitting and force the piston from the caliper.
  4.  


CAUTION
Do not apply the air pressure suddenly or the piston may shoot out, injuring your fingers.

  1. Remove the seal from the piston. Clean all parts with alcohol or brake fluid. Inspect the piston for scoring, replace if necessary.
  2.  
  3. Hone the caliper bore and clean with brake fluid or alcohol.
  4.  
  5. Install a new seal on the piston, lubricate the piston and caliper bore. Install the piston into the caliper bore and seat the bottom of its travel. Install the dust shield.
  6.  
  7. Be sure the brake pads are installed correctly on the support and reinstall the caliper.
  8.  
  9. Connect the brake line, refill the master cylinder and bleed the brake system.
  10.  

1979-84 Front Wheel Drive Without Turbo
  1. Remove the caliper.
  2.  
  3. Remove the caliper bridge bolts.
  4.  
  5. Separate the inner and outer caliper halves.
  6.  
  7. Remove the torque plate from the inner caliper half.
  8.  
  9. Remove the dust seal from the piston and discard it.
  10.  
  11. Apply low pressure compressed air to the brake line hose in the caliper, and force the piston out of its bore. Keep your fingers out of the way of the piston, as it often will pop out with considerable force.
  12.  
  13. Remove the seal from the piston, being careful to avoid scratching the piston surface.
  14.  
  15. Clean all parts in alcohol. Discard all rubber parts.
  16.  
  17. Replace the piston if it appears worn, damaged or pitted.
  18.  
  19. Using a rebuilding kit, replace all worn and rubber parts. Most kits for these brakes contain two types of grease. One type is colored red; the other, yellow. The yellow grease is applied to the torque plate shafts. The red grease goes on the piston seal. If this type of kit is not available, use rubber grease on the seal and silicone grease on the shafts.
  20.  
  21. Assemble the caliper. Don't forget to grease the seal and shafts. Torque the bridge bolts to 58-69 ft. lbs.
  22.  

1985-89 Models and 1984-89 Colt Turbo
  1. Remove the caliper assembly from the car.
  2.  
  3. Remove the pads.
  4.  
  5. Remove and discard the piston dust boot.
  6.  
  7. Apply low pressure compressed air to the brake line hose in the caliper, and force the piston out of its bore. Keep your fingers out of the way of the piston, as it often will pop out with considerable force.
  8.  
  9. Remove the seal from the piston, being careful to avoid scratching the piston surface.
  10.  
  11. Clean all parts in alcohol. Discard all rubber parts.
  12.  
  13. Replace the piston if it appears worn, damaged or pitted. Replace all rubber parts.
  14.  
  15. Coat the piston and bore with clean brake fluid.
  16.  
  17. Coat the piston seal with rubber grease. Install it on the piston.
  18.  
  19. Insert the piston into the bore, being careful to avoid twisting the seal.
  20.  
  21. Apply silicone grease to the new dust boot and install it.
  22.  
  23. Install the caliper and brake pads. Coat the pin bolt threads with clean brake fluid on Colt without a turbocharger; RTV silicone sealant on Colt Turbo and Vista.
  24.  

 
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