Rear
CALIPER-REAR DISC BRAKEREMOVAL
NOTE: Before proceeding, Refer to Service Precautions.
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.
3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly.
4. Remove the banjo bolt (1) connecting the brake hose (4) to the brake caliper (3). There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers; install new washers upon installation.
NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged.
5. Remove the two caliper guide pin bolts (4).
6. Remove the caliper assembly (1) from the brake adapter by first rotating the top of the caliper away from the rotor (2), and then lifting the caliper assembly off the lower machined abutment (4) on the adapter.
7. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip (3) over the raised area on the caliper (1). Slide the brake pad off of the brake caliper.
8. Pull the inboard brake pad away from caliper piston until the retaining clip (1) is free from the cavity in the piston (2). Remove the pad.
DISASSEMBLY
GUIDE PIN BUSHINGS
Before disassembling the brake caliper, clean and inspect it.
NOTE: Use the following steps to remove each guide pin bushing and sleeve.
1. Push the guide pin bushing sleeve (3) towards the back of the caliper (1), then pull the sleeve out the back of the caliper bushing (2).
2. Once the sleeve is removed, collapse one side of the rubber guide pin bushing (2). Pull the bushing out the opposite side of the brake caliper (1) mounting boss.
PISTON AND SEAL
Before disassembling the brake caliper, clean and inspect it.
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.
1. 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.
2. Place a wooden block (1) in the caliper as shown.
3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out.
4. Remove the piston from the caliper. Discard the piston.
5. Using an appropriate tool (2), remove the dust boot (3) from the caliper (1) and discard it.
CAUTION: Do not use a screwdriver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges.
6. Using a soft tool such as a plastic trim stick (1), work the piston seal (4) out of its groove (3) in the caliper piston bore. Discard the used seal.
7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
8. Inspect the piston 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. Bores that have deep scratches or scoring may be honed. Do not over-hone the bore. Do not increase the diameter of the bore more than 0.0254 mm (0.001 inch). If the bore does not clean up within this specification, a new disc brake caliper needs to be installed.
NOTE: If honing the bore, during the honing procedure, coat the stones and bore with clean brake fluid. After honing is complete, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper bore with fresh clean brake fluid, then wipe it dry with a clean, lint free cloth, and then clean it a second time.
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
GUIDE PIN BUSHINGS
NOTE: Use the following steps to install each guide pin bushing and sleeve.
1. Fold the guide pin bushing (1) in half lengthwise.
NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing in the caliper boss.
2. Insert the folded bushing (2) into the caliper (1) mounting boss until it is centered in the boss.
3. Unfold the bushing using fingers or a wooden dowel until the bushing is fully seated against the caliper boss bore. The bushing flanges should be evenly seated (1) on both sides of the mounting boss (2).
4. Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent.
5. Starts the guide pin sleeve (1) into one end of bushing (2) until the sleeve leading end seal groove is past the seal area of the bushing convoluted boot.
6. While holding the convoluted boot on the opposite end of the bushing, continue to push the sleeve through the bushing until the bushing boot is fully seated into the outboard seal groove on that end of sleeve.
7. Seat the opposite end bushing boot into the groove on the trailing end of the bushing sleeve.
8. Verify both ends of the bushing are properly seated in the sleeve outboard grooves. When the sleeve is seated properly into the bushing, the sleeve/bushing can be easily slid back and forth without the bushing unseating from the sleeve groove.
PISTON AND SEAL
NOTE: Always have clean hands when assembling a brake caliper.
NOTE: Always use fresh, clean brake fluid when assembling a brake caliper.
CAUTION: 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 bore. The seal (1) should be started at one area of the groove and gently worked around and into the groove using only finger pressure to seat it.
2. Coat the inside of the NEW piston dust boot with clean brake fluid.
3. Install the dust boot (1) over the piston (2) and into the groove at the top of the piston. Stretch the boot downward, straightening the folds, then move it back upward. Repeat as necessary until the all the folds snap uniformly into place.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
4. Install the piston (1) into the caliper (2) by pushing it past the piston seal until it bottoms in the caliper bore.
5. Position the dust boot in the top of the counterbore of the caliper piston bore.
6. Using a hammer with Installer (2), Special Tool C-4689, and Handle (1), Special Tool C-4171, drive the boot into the counterbore of the caliper (3).
7. Install the caliper on the vehicle and bleed the brakes as necessary.
INSTALLATION
CAUTION: When installing new brake components, be sure to use correct parts. Parts designed for BR4. Performance Brake System must not be mixed with other brake systems. These parts, similar in appearance, can be easily identified.
1. If not already present, 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. Install the inboard brake pad into the caliper piston (2) by firmly pressing the pad in with the thumbs. Be sure the inboard brake pad is positioned squarely against the face of the caliper piston once installed.
3. Slide the outboard brake pad (2) onto the caliper. Be sure the retaining clip (3) is squarely seated in the depressed areas on the caliper beyond the raised retaining bead (1).
4. Lubricate both adapter caliper slide abutments (3, 4) with a liberal amount of Mopar Multipurpose Lubricant or equivalent.
CAUTION: Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter.
5. Starting with the lower end, carefully guide the caliper (1) and brake pads over the brake rotor (2). First catch the caliper's bottom edge behind the caliper slide abutment (4), then rotate the top of the caliper into mounted position on the upper abutment (3).
CAUTION: Extreme caution should be taken not to cross-thread the caliper guide pin bolts (4) when they are installed.
6. Carefully install the caliper guide pin bolts (4). Tighten the bolts to 22 Nm (192 inch lbs.).
7. Install the banjo bolt (1) connecting the brake hose to the brake caliper. Install NEW washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm (210 inch lbs.).
8. Install tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.).
9. Lower the vehicle.
10. Remove the brake pedal holding tool.
11. Bleed the caliper as necessary.
12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.