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 aftermarket 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
During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub.

Handling of the brake rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings.

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, 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.

NOTE: Starting with the 1998 model year, different lining material is used on the disc brake shoes depending on the type of brake system the vehicle is equipped with. Vehicles equipped with standard front disc and rear drum brakes use a new lining material on the front disc brake shoes. Vehicles that are equipped with optional 4 wheel disc brakes use a new lining material on both the front and rear disc brake shoes. When new brake shoes are installed, be sure brake shoes for the correct model year and type of brake system the vehicle is equipped with are used.

REMOVE
1. Raise vehicle on jackstands or centered on a hoist.
2. Remove the front wheel and tire assemblies from vehicle.

Caliper Guide Pin Bolts:

3. Remove the 2 guide pin bolts mounting the caliper to the steering knuckle.

Removing Caliper From Steering Knuckle:

4. Remove brake caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle.

Storing Caliper:

5. Support caliper firmly to prevent weight of caliper from damaging the flexible brake hose.

Removing/Installing Brake Rotor:

6. Remove brake rotor from hub by pulling it straight off the wheel mounting studs.

Removing Outboard Brake Shoe:

7. Remove outboard brake shoe by prying the shoe retaining clip over raised area on caliper. Then slide the brake shoe down and off the caliper.

Removing Inboard Brake Pad From Piston:

8. Pull the inboard brake shoe away from the caliper piston until the retaining clip is out of the cavity in the 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).

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. 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 shoes (if equipped).

Front Brake Shoe Identification:

NOTE: The inboard and outboard brake shoes are not common.

Inboard Brake Shoe:

5. Install the new inboard brake shoe into the caliper piston by firmly pressing into piston bore with thumbs. Be sure inboard brake shoe is positioned squarely against the face of the caliper piston.

Installing Outboard Brake Shoe:

6. Slide the new outboard brake shoe onto the caliper.

CAUTION: Use care when installing the caliper onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.

Installing Caliper On Steering Knuckle:

7. Carefully position the brake caliper and brake shoes over the rotor by hooking the end of the caliper under the steering knuckle. Then rotate caliper into position on steering knuckle.
8. Install the caliper guide pin bolts and tighten to 18 - 20 Nm (192 inch lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts.
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 pads.