Removal and Installation
WARNING: Although factory installed brake linings are made from asbestos free materials, some after market brake lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when after market brake linings may have been installed on the vehicle. Always wear a respirator when cleaning brake components as asbestos can cause serious bodily harm such as asbestosis and or cancer. Never clean brake components by using compressed air, use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner is not available, clean brake parts using only water dampened shop towels. Do not create brake lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended safety practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA), for handling and disposal of products containing asbestos.GENERAL INFORMATION
If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately.
During removal and installation of a wheel and tire assembly, use care not to strike the caliper.
NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist.
2. Remove front wheel and tire assemblies from vehicle.
CAUTION: When prying the piston back into the bore of the caliper do not use a hard pry bar. The use of a hard pry bar will damage the braking surface of the rotor.
3. Slightly pry the piston back into the bore of the disc brake caliper. The piston is to be pried back by inserting a soft tool (such as a trim stick) between the inboard brake shoe and the rotor and prying against the inboard brake shoe. This will force the piston back into the caliper.
Removing Caliper Guide Pin Bolts:
4. Remove the 2 brake caliper to steering knuckle guide pin bolts.
Removing/Installing Brake Caliper:
5. Remove brake caliper from steering knuckle, by first rotating bottom of brake caliper away from the steering knuckle. Then slide top of brake shoes down and out from the top machined abutment on steering knuckle.
Storing Caliper:
6. Support brake caliper from upper control arm to prevent weight of caliper from being supported by brake flex hose. Supporting disc brake caliper from flex hose can damage the hose.
Removing/Installing Brake Rotor:
7. Remove the brake rotor from the front hub.
Removing/Installing Outboard Brake Shoe:
8. Remove outboard brake shoe by pushing the brake shoe inward until retaining pins on brake shoe can be removed from holes in caliper. Then slide the brake shoe off the caliper.
Removing Inboard Brake Pad From Piston:
9. Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston.
CALIPER INSPECTION
Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Caliper Disassembly And Re-Assembly Procedures.
Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle.
INSTALL
1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for caliper installation with new brake shoe assemblies.
2. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.
3. Install the front rotor on the hub, making sure it is squarely seated on face of hub.
4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped).
Front Brake Shoe Assembly Identification:
NOTE: The inboard and outboard brake shoes are not common. Be sure the correct outer brake shoe is installed in the correct caliper. The left and right outer brake shoes are different and must be installed correctly. The wear sensor and the hold down clip must be on the upper end of the caliper when the caliper and brake shoes are installed on the steering knuckle.
Inboard Brake Shoe:
5. Install the new inboard brake shoe assembly into the caliper piston by firmly pressing into piston bore. Be sure inboard brake shoe assembly is positioned squarely against face of caliper piston.
6. Slide the new outboard brake shoe assembly onto the caliper assembly.
CAUTION: Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. Also, make sure that caliper guide pin bushings and sleeves are clear of the steering knuckle bosses.
Removing/Installing Brake Caliper:
7. Carefully position brake caliper and brake shoes over brake rotor by first hooking top of brake shoes onto upper abutment on steering knuckle. Then rotate caliper into position at bottom of steering knuckle.
NOTE: When installing guide pin bolts, extreme caution should be taken not to cross thread the caliper guide pin bolts.
8. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (16 ft. lbs.).
9. Install the wheel and tire assembly.
10. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
11. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal.
12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.