PT Cruiser, 2001 - 2005

Brake Pads


Removal & Installation

  1. Before servicing the vehicle, refer to the Precautions section.
  3. Remove or disconnect the following:

    Front wheels
    2 caliper to steering knuckle guide pin bolts
    Caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then, slide the opposite end of the caliper out from under the machined end of the steering knuckle.

  5. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose that will damage the hose.

    Brake pads from the caliper
    Outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then, slide the pad down and off the caliper
    Inboard brake pad by pulling it away from the piston until the retaining clip is free from the cavity in the piston.
    Rotor, if necessary, by pulling it straight off the wheel mounting studs

    Click image to see an enlarged view

    Fig. Disc brake pad identification



To install:

  1. Clean all parts well. Inspect the caliper for piston seal leaks (brake fluid in and around the boot area and inboard lining) and for any ruptures of the piston dust boot. If the boot is damaged or fluid leak is visible, disassemble the caliper and install a new seal and boot (and piston, if scored).
  3. Inspect the caliper pin bushings. Replace if damaged, dry or brittle.
  5. Completely compress the piston into the caliper using a large C-clamp or other suitable tool.
  7. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease.
  9. Install or connect the following:
    Be sure to remove the noise suppression gasket paper cover if the pads come so equipped.

    Rotor if removed
    Brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake shoe assembly is positioned squarely against the face of the caliper piston.

    Caliper and brake shoe assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then, rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
    Caliper guide pin bolts and torque to 26 ft. lbs. (35 Nm) on the front caliper or 192 inch lbs. (22 Nm) on the rear caliper
    Wheels and torque the mounting bolts to 100 ft. lbs. (135 Nm)

  11. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
  13. Road test the vehicle for proper operation.