Removal and Installation

REMOVAL AND INSTALLATION





INSTALLATION SERVICE POINT
>>A<< Rear Brake Assembly Installation





1. In order to measure brake drag torque after pad installation, measure hub torque with the pads removed.
Use a spring scale to measure hub torque in the direction shown. Record the value.

CAUTION: Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs.





2. after re-installing the caliper support, install the pad clips and pads to the caliper support.
3. Clean the piston and insert it into the cylinder with special tool MB990520.
4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and installing the guide pin.
5. Check brake drag force as follows:
1. Start the engine and hold the brake pedal down for five seconds. [Pedal depression force: approximately 196 N (44 pound)]
2. Stop the engine.
3. Turn the brake disc forward ten times.





4. Use a spring scale to measure the hub torque with pads installed in the same direction as earlier.
5. Calculate the drag force of the disc brake [difference between hub torque with pads installed and hub torque with pads removed].
Standard value: 69 N (16 pound) or less
6. If the drag torque exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.

INSPECTION
Brake Disc Check
Disc wear
Disc run-out
Disc inside diameter





DISASSEMBLY AND ASSEMBLY





LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS
When disassembling the disc brakes, disassemble both sides (left and right) as a set.
<> Piston Boot/Piston Removal

CAUTION: Blow air little by little to remove the piston. The piston will rush out if a force of air is applied suddenly.

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose connection hole to remove the piston boot and piston.
<> Piston Seal Removal

CAUTION: Do not use a flat-tipped screwdriver or similar tool to remove piston seal. These may damage the inner side of the cylinder.

1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with trichloroethylene, alcohol, or specified brake fluid MOPAR(R) Brake Fluid/Conforming to DOT 3 or DOT 4.

ASSEMBLY SERVICE POINT
>>A<< Lock Pin/Guide Pin Installation

Install the guide pin as illustrated that each head mark of the guide pin and the lock pin matches the indication mark ("G" or "L") located on the caliper body.

INSPECTION
- Check the cylinder for wear, damage or rust.
- Check the piston surface for wear, damage or rust.
- Check the caliper body or sleeve for wear.
- Check the pad for damage or adhesion of grease, check the backing metal for damage.

PAD WEAR CHECK

WARNING:
^ Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which may cause unreliable brake operation.
^ If there is significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin.

Measure thickness at the thinnest and most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)