Brake Caliper
DISC BRAKE CALIPER FRONTREMOVAL (CONTINENTAL TEVES BRAKES)
1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir.
2. Raise the vehicle.
3. Remove front wheel and tire assembly.
4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers.
5. Remove the 2 caliper guide pin bolts.
6. Remove the brake caliper from the adapter.
REMOVAL (TRW BRAKES)
1. Using a brake pedal holding tool, 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 when the lines are opened.
2. Raise the vehicle.
3. Remove the front tire and wheel assembly
4. Remove the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers.
5. Remove the two brake caliper guide pin bolts (Fig. 31).
6. Remove the disc brake caliper from the disc brake adapter.
DISASSEMBLY (CONTINENTAL TEVES BRAKES)
Before disassembling the brake caliper, clean and inspect it.
1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss.
2. Repeat this procedure on the remaining bushing.
DISASSEMBLY - CALIPER PISTON AND SEAL
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.
NOTE: Before disassembling the brake caliper, clean and inspect it.
NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system.
1. Remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers.
2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out.
3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle.
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.
5. Remove the piston dust boot from the caliper and discard.
NOTE: 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.
Fig. 32 Removing Piston Seal:
6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 32). Discard the old 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.
CLEANING - CALIPER
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 - CALIPER
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 (CONTINENTAL TEVES BRAKES)
1. Fold the guide pin bushing in half lengthwise.
NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing.
2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper.
3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole.
4. Lubricate inside surfaces of bushing using Mopar Dielectric Grease or equivalent.
5. Repeat the procedure for remaining bushing.
ASSEMBLY - CALIPER PISTON AND SEAL
NOTE: Never use an old piston seal.
Fig. 33 Installing New Piston Seal:
1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 33) using only your clean fingers to seat it.
2. Coat the new piston boot with clean brake fluid.
3. Position the dust boot over the piston after coating it with 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.
Fig. 34 Installing Piston Into Caliper Bore:
4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 34).
5. Position the dust boot into the counterbore of the caliper assembly piston bore.
Fig. 35 Installing Dust Boot:
6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 35).
7. Reinstall the caliper on the vehicle and bleed the brakes as necessary.
INSTALLATION (CONTINENTAL TEVES BRAKES)
CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur.
1. Completely retract the caliper piston back into piston bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
CAUTION: Use care when installing the brake caliper assembly onto the steering knuckle, so that the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.
2. Carefully position the brake caliper and shoes over the brake rotor and adapter.
3. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts.
4. Install the anti-rattle clip on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special copper washers.
5. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 Nm (35 ft. lbs.).
6. Install the wheel and tire assembly. 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.).
7. Lower the vehicle.
8. Remove the brake pedal depressor (holding) tool.
9. Bleed the hydraulic brake circuit to the brake caliper.
10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.
INSTALLATION (TRW BRAKES)
CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur.
1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins.
2. Install the disc brake caliper over the brake shoes on the brake caliper adapter.
3. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 31).
4. Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). Install NEW copper 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 a torque of 47 Nm (35 ft. lbs.).
5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.).
6. Lower the vehicle.
7. Remove the brake pedal holding tool.
8. Bleed the caliper as necessary.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.