Rear
PADS-REAR BRAKEREMOVAL
NOTE: Before proceeding, Refer to Service Precautions.
1. Raise and support the vehicle.
NOTE: Perform Step 2 through Step 7 on each side of the vehicle to complete pad set removal.
2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
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 pads 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.
3. Remove the two caliper guide pin bolts (4).
4. 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.
5. Hang the brake caliper from rear strut using wire or cord to prevent the weight of the caliper from damaging the brake hose.
6. 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.
7. 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.
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.
INSPECTION
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors.
If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the calipers.
Measure each brake pad. The combined brake pad and its lining material thickness should be measured at its thinnest point. For rear disc brake pads, when a set of brake pads are worn to a thickness of approximately 9.0 mm (3/8 inch), they should be replaced.
NOTE: It is important to inspect both front and rear brake pads during the same inspection. Typically, front and rear brake pads wear out at the same time.
Replace both disc brake pads (inboard and outboard) on each caliper. It is necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection.
If the brake pads do not require replacement, be sure to reinstall the brake pads in the original position they were remove from.
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.
NOTE: Perform Step 1 through Step 7 on each side of the vehicle to complete pad set installation, then proceed to Step 8.
1. Completely retract the caliper piston back into the piston bore of the caliper. This is required to gain the necessary pad-to-rotor clearance for the caliper installation onto the steering knuckle.
2. Install the inboard brake pad into the caliper piston (2) by firmly pressing the pad in using hand pressure. 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 tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.).
8. Lower the vehicle.
9. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving the vehicle.
10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads.