CALIPER-REAR DISC BRAKE
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING) (Refer to 5 - BRAKES - CAUTION).
1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected.
2. Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly.
4. Unthread the brake tube nut (2) at the rear flex hose.
5. Remove the clip (3) securing the rear flex hose to the trailing link mounted bracket. Remove the flex hose from the bracket.
6. Unthread and remove the brake flex hose (4) from the brake caliper (1).
NOTE: When removing the caliper guide pin bolts (2, 3), note that one bolt has a special sleeve on the tip and the other does not. Depending on the build date, this special sleeve bolt (3) can be located in either the top or bottom location. When installing, make sure the bolts are put back in the same locations as when removed to avoid NVH issues.
7. Remove the two brake caliper guide pin bolts (2, 3).
8. Slide and remove the disc brake caliper (1) with outboard brake pad attached from the disc brake adapter bracket, inboard brake pad and rotor.
9. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper.
DISASSEMBLY
NOTE: Before disassembling the brake caliper, remove it from the vehicle. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - REMOVAL)
NOTE: Before disassembling the brake caliper, clean and inspect it. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - CLEANING) (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSPECTION)
1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the boot snap-ring.
2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1) making sure not to damage the dust boot, piston or piston bore.
3. Carefully pull the piston dust boot away from the caliper boot groove.
WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion.
4. Mount the caliper in a vise equipped with protective jaws.
WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure.
5. Place a wooden block (2) in the caliper as shown.
6. As necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston (1) out.
7. Remove the piston (with dust boot) from the caliper.
8. Remove the dust boot from the piston and discard it.
CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges.
9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in the caliper piston bore. Discard the used seal.
10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
11. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth.
CLEANING
WARNING: 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.
To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar® Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals.
INSPECTION
Inspect the disc brake caliper for the following:
- Brake fluid leaks in and around boot area and inboard lining
- Ruptures, brittleness or damage to the piston dust boot
- Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots.
ASSEMBLY
NOTE: Always have clean hands when assembling a brake caliper.
NOTE: Always use fresh, clean brake fluid when assembling a brake caliper.
NOTE: Never use an old piston seal.
1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it.
2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot.
3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown.
4. Coat the piston with clean brake fluid.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore.
6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot.
7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it.
8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring.
9. Install the caliper on the vehicle and bleed the brakes as necessary. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSTALLATION)
INSTALLATION
1. If not already performed, completely retract the caliper piston back into the piston bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
2. Slide the outboard brake pad onto the caliper. Be sure the retaining clip is squarely seated in the depressed areas on the caliper beyond the raised retaining bead.
CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the guide pin boots.
3. Install the disc brake caliper with outboard brake pad attached over the inboard brake pad and rotor, onto the brake caliper adapter bracket.
NOTE: When installing the caliper guide pin bolts (2, 3), make sure the bolts are put back in the same locations as when removed to avoid NVH issues. Depending on the build date and services performed, the location of the bolt with the special sleeve on the tip (3) can vary.
4. Align the caliper guide pin bolt holes with the adapter bracket. Install the lower (with special sleeve) (2) and upper (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 N·m (32 ft. lbs.).
5. Thread the rear brake flex hose (4) into the brake caliper (1). Tighten the flex hose fitting at the caliper to 15 N·m (133 in. lbs.).
6. Route and install the brake flex hose into the trailing link mounted bracket. Install the clip (3) securing the flex hose to the bracket.
7. Thread the brake tube nut (2) into brake flex hose. Tighten the brake tube nut to 17 N·m (150 in. lbs.).
8. Install the tire and wheel assembly (1) (Refer to 22 - TIRES/WHEELS - INSTALLATION). Install and tighten the wheel mounting nuts (3) to 135 N·m (100 ft. lbs.).
9. Lower the vehicle.
10. Remove the brake pedal holding tool.
11. Bleed the caliper as necessary. (Refer to 5 - BRAKES - STANDARD PROCEDURE)
12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.