Durango, 2001-2005

Brake Caliper

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Install prop rod on the brake pedal to keep pressure on the brake system.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Remove the wheel and tire assembly.
  8.  
  9. Drain small amount of fluid from master cylinder brake reservoir with suction gun.
  10.  
  11. Remove the brake hose banjo bolt if replacing caliper.
  12.  
  13. Remove the caliper mounting slide pin bolts.
  14.  
  15. Remove the caliper from vehicle.
  16.  

To install:

  1. Install caliper to the caliper adapter.
  2.  
  3. Coat the caliper mounting slide pin bolts with silicone grease. Then install and tighten the bolts to 11 ft. lbs. (15 Nm).
  4.  
  5. Install the brake hose banjo bolt and new copper seal washers if caliper was removed.
  6.  
  7. Install the brake hose to the caliper with and tighten fitting bolt to 21 ft. lbs. (28 Nm).
    CAUTION
    Verify brake hose is not twisted or kinked before tightening fitting bolt.

  8.  
  9. Remove the prop rod from the vehicle.
  10.  
  11. Bleed the base brake system.
  12.  
  13. Install the wheel and tire assemblies.
  14.  
  15. Remove the supports and lower the vehicle.
  16.  
  17. Verify a firm pedal before moving the vehicle.
  18.  

 
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