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

Brake Pads

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INSPECTION



The brake pad thickness can usually be checked (on most models) by removing the front (or rear, models equipped) wheel, and looking through the cutout at the top of the brake caliper. Replace the pads if uneven wear (inner and outer pads) is determined. Always replace the brake pads as a set (both wheels).

REMOVAL & INSTALLATION





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Fig. Fig. 1 View of the front disc brake components



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Fig. Fig. 2 Loosen the lower sleeve bolt from the caliper ...



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Fig. Fig. 3 ... and remove



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Fig. Fig. 4 Rotate the caliper upwards and suspend



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Fig. Fig. 5 Remove the pad clips and slide the pads off the mounting bracket



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Fig. Fig. 6 Remove and inspect all retainer clips



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Fig. Fig. 7 Use a C-clamp to force the piston back into the caliper

1971 to Mid-1973 Models


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Fig. Fig. 8 Exploded view of the front disc brake pads and caliper-1971-73 models

Always replace both left and right-hand sets when replacing brake pads. Replace pads before they are worn past 2mm.

  1. Loosen the wheel lug nuts, block the rear wheels and then raise the front of the car and support it on stands. Remove the wheels.
  2.  
  3. Pry the cross-spring from the pads. Pull out the retaining clips and remove the pins.
  4.  
  5. Using a pair of locking pliers, pull the one pad out of the caliper.
  6.  
  7. Siphon off about 1 / 2 of the brake fluid in the reservoir. This prevents air overflow when the pistons are pushed back for the new pad.
  8.  

To install:

  1. Push the caliper piston back with a flat piece of metal or smooth hardwood and a large C-clamp. Place the piece of metal or wood against the piston. Position the C-clamp, centered on the wood and over the caliper and push the piston into its bore by tightening the clamp.
  2.  
  3. Insert the new pad along with its shim (arrow on shim pointing forward).
  4.  

If you have a 1971 or early 1972 Colt and have been experiencing brake squeaking, replace the shims with the newer square type.

  1. Remove the opposite pad and repeat Steps 5 and 6.
  2.  
  3. Install the retaining pins and clips. Install the cross-spring as shown in the illustration.
  4.  
  5. Repeat the above operation on the other wheel.
  6.  
  7. Fill the master cylinder (bleed the system if necessary) and lower the car. Pump the brakes several times. Do not move the car until a firm brake pedal is present.
  8.  

Mid 1973-83, Rear Wheel Drive

Except Station Wagon and Challenger

  1. Follow the preceeding procedure through Step 1.
  2.  
  3. Pry the dust shield off the top of the caliper by lifting the clip in the center of the shield with a screwdriver.
  4.  
  5. Using needlenose pliers, unsnap the M-clip from the brake pad and the two retaining pins.
  6.  
  7. Remove the K-clip from the holes in the retaining pins.
  8.  
  9. Use a small punch or screwdriver to tap the retaining pins out of the caliper.
  10.  
  11. Grip the ears of each brake pad with a pliers and pull it from the caliper. Minimum serviceable thickness for the brake lining on the pad is 2mm. Always replace both sets at the same time.
  12.  

To install:

  1. Using a flat piece of hardwood and C-clamp, push the piston back into the cylinder.
  2.  
  3. Install the pads in the caliper.
  4.  
  5. Insert the retaining pins and install the K and M-clips. Be sure that they are installed properly in the positions from which they were removed. Fill the master cylinder (bleed the system if necessary) and lower the car. Pump the brakes several times. Do not move the car until a firm brake pedal is present.
  6.  

1973 and Later


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Fig. Fig. 9 Exploded view of the front disc brake sliding type caliper

A sliding caliper 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. Remove the spring pin(s) and pull the stopper plug(s) from the upper end of the caliper.
  6.  
  7. Move the caliper back and forth to loosen, then remove the caliper from the support.
  8.  

The hydraulic brake hose need not be removed from the caliper, but do not allow the caliper weight to hang from the hose. Secure the caliper with a piece of wire.

  1. Take the time to examine the pad holder with its related clips and springs. All parts must be returned to the same place when reinstalling the old pads or replacing with new pads.
  2.  
  3. Remove the anti-squeak clips then remove the brake pads from the mounting bracket. Do not remove the caliper support springs (two large wire hair pins).
  4.  

To install:

  1. Under each brake pad there is a pad support plate. These are not interchangeable and must be installed correctly.
  2.  
  3. Insert the new pads in the mounting bracket over the pad support plates and install the anti-squeak clips.
  4.  
  5. Seat the caliper piston fully into the caliper bore. Do this by opening the bleeder screw and push the piston in with a hammer handle, or C-clamp. If you meet too much resistance, the piston might be hanging up on a scored bore or have a gaulded piston wall, if so rebuild or replace the caliper.
  6.  
  7. Seat the caliper over the mounting bracket. Clean and apply No. 2 brake grease to the sliding surfaces, plug plates and stopper plug. Install the caliper stopper plug and the spring pin.
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Install the tire and wheel, lower the car to the ground and road test. Pump the brakes several times. Do not move the car until a firm brake pedal is present.
  12.  

1979-84 Front Wheel Drive Without Turbo


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Fig. Fig. 10 Exploded view of the front disc caliper on the front wheel drive vehicles without Turbo-1979-84 models

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Pry off the dust shield from the caliper.
  6.  
  7. Depress the center of the outboard spring clip and remove the clip by slipping the ends from the pins.
  8.  
  9. Remove the inboard spring clip with pliers.
  10.  
  11. Using pliers, pull the retaining pins from the caliper.
  12.  
  13. Lift the pads and anti-squeal shims from the caliper.
  14.  

To install:

  1. Clean all caliper parts, especially the torque plate shafts, with a solvent made for brake parts.
  2.  

Replace all brake pads at the same time. Never replace the pads on one wheel only!

  1. If the dust protector or spring clips are weak, damaged or deformed, replace them.
  2.  
  3. Remove the cap from the master cylinder reservoir and, using a clean suction gun, remove about 1 / 4 inch of fluid.
  4.  
  5. Using a C-clamp, force the caliper piston back into the caliper as far as it will go.
  6.  
  7. Install the inboard pad and anti-squeal shim.
  8.  
  9. Install the outboard pad and anti-squeal shim.
  10.  
  11. Install the pins.
  12.  
  13. Install the two spring clips.
  14.  
  15. Install the dust shield.
  16.  
  17. Install the wheels and lower the car. Get in the car and depress the brake pedal a few times. The first couple of strokes on the pedal will feel overly long. However, the pads will set themselves and the stroke will return to normal. Pump the brakes several more times. Do not move the car until a firm brake pedal is present.
  18.  

1985-89 Colt Without Turbo


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Fig. Fig. 11 Exploded view of the front disc caliper on 1985 Colts without Turbo

  1. Raise and support the front end on jackstands. Remove the wheels.
  2.  

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 pin torque is 16-23 ft. lbs.

  1. Remove the lower sleeve bolt from the caliper and rotate the caliper upward.
  2.  

There is a grease coating on the bolt. Make sure that it is not removed or contaminated.

  1. Support the caliper by suspending it with wire or string from a nearby suspension member.
  2.  
  3. Remove the inner, then outer shims from the caliper.
  4.  
  5. Lift out the brake pads.
  6.  
  7. Remove the pad liners.
  8.  
  9. Clean all parts in solvent made for brake parts.
  10.  

To install:

  1. Inspect the dust boot on the caliper piston. If it is torn or brittle, replace it, and consider rebuilding the caliper.
  2.  
  3. Inspect the shims and liners and replace them if damaged.
  4.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Remove the cap from the master cylinder reservoir and siphon off about 1 / 4 inch of fluid.
  2.  
  3. Using a C-clamp, force the piston back into the caliper as far as it will go. Remove the clamp.
  4.  
  5. Install the liners, pads and inner, then outer shims.
  6.  

Never replace just one set of pads, pads should be replaced on both front wheels at the same time.

  1. Lower the caliper and install the lower sleeve bolt. Torque the bolt to 16-23 ft. lbs.
  2.  
  3. Start the engine and depress the brake pedal several times. Hold it depressed for about 5 seconds. Turn the engine off.
  4.  
  5. Rotate the brake rotor a few times. Using a spring scale hooked to one of the lugs, measure the brake drag. Remove the pads and perform the spring scale test again. The difference between the drag test with and without the pads should not exceed 15 lbs. If the difference does exceed 15 lbs., the caliper will have to be rebuilt or replaced. Service if required. When servicing is complete, pump the brakes several times. Do not move the car until a firm brake pedal is present.
  6.  

1984-89 Colt Turbo 1985-89 Vista


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Fig. Fig. 12 Exploded view of the front disc brake pads and caliper-Colt Turbo and Vista models

  1. Raise and support the front end on jackstands. Remove the front wheels.
  2.  

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 lower pin bolt and rotate the caliper upwards. Support the caliper with wire or string from a nearby suspension member.
  2.  
  3. Remove the inner shim, the anti-squeal shim and the pads from the caliper support assembly.
  4.  
  5. Remove the clips from the pads.
  6.  
  7. Clean all parts in solvent made for brake parts.
  8.  

To install:

  1. Inspect the dust boot on the caliper piston. If it is torn or brittle, replace it, and consider rebuilding the caliper.
  2.  
  3. Inspect the shims and liners and replace them if damaged.
  4.  
  5. Remove the cap from the master cylinder reservoir and siphon off about 1 / 4 inch of fluid.
  6.  
  7. Using tool MB990520, force the piston back into the caliper as far as it will go. Remove the clamp.
  8.  
  9. Install the pads with clips attached and the proper shims, in position, on the support.
  10.  

Never replace just one set of pads. Pads should be replaced on both front wheels at the same time.

  1. Lower the caliper and install the lower pin bolt. Torque the bolt to 16-23 ft. lbs.
  2.  
  3. Start the engine and depress the brake pedal. Hold it depressed for about 5 seconds. Turn the engine off.
  4.  
  5. Rotate the brake rotor a few times. Using a spring scale hooked to one of the lugs, measure the brake drag. Remove the pads and perform the spring scale test again. The difference between the drag test with and without the pads should not exceed 15 lbs. If the difference does exceed 15 lbs., the caliper will have to be rebuilt or replaced.
  6.  
  7. When servicing is complete, pump the brakes several times, do not operate the vehicle until a firm brake pedal is present. Bleed the brakes if necessary.
  8.  

Conquest


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Fig. Fig. 13 Exploded view of the front disc brake pads and caliper-Conquest models



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Fig. Fig. 14 With a spring scale attached to a stud, measure the brake drag

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the caliper lower slide pin.
  6.  

There is a grease coating on the bolt. Make sure that it is not removed or contaminated.

  1. Rotate the caliper upward and suspend it with string from a nearby suspension member.
  2.  
  3. Remove the brake pads and shims.
  4.  
  5. Remove the clips from the pads.
  6.  
  7. Clean all parts in solvent made for brake parts.
  8.  

To install:

  1. Inspect the dust boot on the caliper piston. If it is torn or brittle, replace it, and consider rebuilding the caliper.
  2.  
  3. Inspect the shims and liners and replace them if damaged.
  4.  
  5. Remove the cap from the master cylinder reservoir and siphon off about 1 / 4 inch of fluid.
  6.  
  7. Using tool MB990520, force the piston back into the caliper as far as it will go. Remove the clamp.
  8.  
  9. Install the pads with clips attached and the proper shims, in position, on the support.
  10.  

Never replace just one set of pads, pads should be replaced on both front wheels at the same time.

  1. Rotate the caliper back into position and install the lower slider pin. Torque the pin to 70 ft. lbs.
  2.  
  3. Start the engine and depress the brake pedal. Hold it depressed for about 5 seconds. Turn the engine OFF.
  4.  
  5. Rotate the brake rotor a few times. Using a spring scale hooked to one of the studs, measure the brake drag. Remove the pads and perform the spring scale test again. The difference between the drag test with and without the pads should not exceed 15 lbs. If the difference does exceed 15 lbs., the caliper will have to be rebuilt or replaced.
  6.  
  7. When servicing is complete, pump the brakes several times, do not operate the vehicle until a firm brake pedal is present. Bleed the brakes if necessary.
  8.  

 
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