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

Brake Caliper

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REMOVAL & INSTALLATION



For Challenger, follow the pad replacement procedure and disconnect the brake lines. For Conquest, follow the pad replacement procedure, then remove the upper pin and disconnect the brake line.

OVERHAUL



Challenger


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Fig. Fig. 1 Remove the ring that retains the lever cap



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Fig. Fig. 2 With snapring pliers, remove the snapring



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Fig. Fig. 3 Remove the automatic adjuster spindle



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Fig. Fig. 4 Remove the caliper piston with compressed air



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Fig. Fig. 5 The spring washer arrangement is very important during installation



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Fig. Fig. 6 Using a special tool to compress the spring washer prior to installing

  1. Remove caliper from support after disconnecting the brake hose.
  2.  
  3. Remove the clevis pin connecting the parking brake lever.
  4.  
  5. Remove the ring that retains the lever cap and the cap. Remove the lever assembly.
  6.  
  7. Remove the automatic adjuster spindle by unscrewing it.
  8.  
  9. Remove the piston boot and the piston. The piston may be pushed from the caliper by inserting a soft round drift through the adjuster spindle hole. Remove the seal from the piston and clean all parts.
  10.  
  11. Hone the caliper bore.
  12.  
  13. Install a new piston and adjuster seal on the piston, lubricate and install into caliper. Seat the piston and install the dust shield (boot). Lubricate and install the adjuster spindle.
  14.  

When installing the adjuster spindle the spring washers must be in the proper direction, i.e. The first, nearest the piston, must curve toward the piston. The second, away from the piston, the third, toward and so on. It may be necessary to apply pressure while installing the lever cap and retaining ring. Install the parking brake lever assembly by reversing the removal procedure.


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. Install the caliper, connect the brake hose and bleed the brakes.
  2.  

Conquest
  1. Follow Steps 1-5 of the Challenger procedure.
  2.  
  3. Press the bushing from the caliper with special tool MB990665.
  4.  
  5. Clean all parts with alcohol. Check all parts for wear or damage. Replace any suspect part. Replace all rubber parts.
  6.  
  7. Assemble all parts in reverse order (refer to the Challenger procedure). Coat all rubber parts sparingly with rubber lubricant. Coat the piston and bore with clean brake fluid. Coat the pins sparingly with silicone grease. When installing the adjuster spindle, screw it in until it turns freely. The spring washer on the spindle must be installed with the first one curving toward the piston then rest curving toward or away alternately.
  8.  

 
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