Single Piston Disc Brake Caliper
CALIPER - FRONT SINGLE PISTON DISC BRAKEREMOVAL
NOTE: Before proceeding, Refer to Service Precautions.
1. Disconnect and isolate battery negative cable (2) from battery post.
2. Using a brake pedal holding tool, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open.
3. Raise and support vehicle.
4. Remove wheel mounting nuts (3), then tire and wheel assembly (1).
5. Remove banjo bolt (6) connecting flexible brake hose (1) to caliper (5). There are two sealing washers (7) (one each side of hose fitting) that will come off when bolt is removed. Discard these washers; install NEW washers on installation.
6. While holding guide pins from turning, remove caliper guide pin bolts (2).
7. Remove brake caliper (1) from brake adapter (3) and pads.
DISASSEMBLY
NOTE: Before disassembling 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. Drain brake fluid from caliper.
2. Mount caliper in a vise equipped with protective jaws.
3. Place a wooden block (2) (padded with approximately one-inch thickness of shop towels) in front of caliper (1) piston as shown. Padded block should be sized to allow piston to push out of bore far enough to be removed by hand after being loosened by air pressure, yet large enough to keep piston from coming completely out. This will cushion and protect caliper piston during removal.
WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure.
4. Apply low pressure compressed air to caliper fluid inlet in short spurts to ease piston out of bore.
5. Remove piston from caliper (1).
CAUTION: When working on disc brake caliper, always use care and suitable tools to avoid damaging the aluminum housing.
6. Using a suitable tool (1), carefully remove dust boot (2) and discard it.
CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch bore or leave burrs on seal groove edges.
7. Using a soft tool such as a plastic trim stick (2), work piston seal (1) out of its groove in caliper piston bore. Discard used seal.
8. Remove caliper bleeder screw (1) from caliper housing (2).
9. Clean piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
10. Inspect both piston and bore for scoring or pitting.
NOTE: It is not recommended to hone caliper bore. The anodized coating would be compromised.
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: Cracked or damaged housing Brake fluid leaks in and around boot area Ruptures, brittleness or damage to the piston dust boot
If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots or replace caliper.
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage caliper seals. Ensure assembly area is clean and dry.
NOTE: Always use new, clean Mopar� DOT 3 Motor Vehicle Brake Fluid or equivalent when assembling brake caliper.
NOTE: Never use used or old piston seals or boots for reassembly.
1. Lubricate caliper piston, piston seal (1) and piston bore (2) with clean, fresh brake fluid.
2. Install NEW piston seal (1) in groove of caliper bore (2). Seal should be started at one area of groove and gently worked around and into the groove using only your clean fingers to seat it.
3. Install NEW dust boot (1) on piston (2) and work boot lip into groove at top of piston. Stretch boot downward, straightening boot folds, then move boot back upward as necessary until folds snap uniformly into place.
4. Install piston (1) into caliper piston (2) bore, pressing piston down to bottom of bore using hand-pressure. Using a piece of wood or wooden hammer handle may also suffice as long as piston and boot damage can be avoided. The dust boot will not seat at this time. Refer to following step.
5. Seat dust boot (3) in caliper counterbore using Installer (2), Special Tool 9315, with Handle (1), Special Tool C-4171. Install dust boot until it bottoms. Do not over-seat dust boot or damage will occur.
6. Install bleeder screw in correct threaded hole. Caliper housing is not side-specific, so it is important to install bleeder screw in threaded hole that will be uppermost once caliper is installed on vehicle. Tighten bleeder screw to 15 Nm (125 inch lbs.) torque.
7. Install caliper on vehicle.
INSTALLATION
CAUTION: Always inspect brake pads before installing disc brake caliper and replace as necessary.
1. Completely retract caliper piston back into bore of caliper. Use hand pressure or a C-clamp may be used to retract piston, first placing a wood block over piston before installing C-clamp to avoid damaging piston.
CAUTION: Use care when installing caliper onto disc brake adapter to avoid damaging boots on caliper guide pins.
2. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
3. Slide caliper over brake pads and onto caliper adapter (3).
CAUTION: Extreme caution should be taken not to crossthread caliper guide pin bolts (2) when they are installed.
4. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 60 Nm (44 ft. lbs.) torque.
5. Install banjo bolt (6) attaching brake hose (1) to caliper (5). Install NEW washers (7) on each side of hose fitting as banjo bolt is placed through fitting. Thread banjo bolt into caliper and tighten to 50 Nm (37 ft. lbs.) torque.
6. Install tire and wheel assembly (1). Tighten wheel mounting nuts (3) to 150 Nm (110 ft. lbs.) torque.
7. Lower vehicle.
8. Remove brake pedal holding tool.
9. Connect battery negative cable (2) to battery post. It is important that this is performed properly.
10. Bleed (1) base brake hydraulic system as necessary.
11. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes.