Chrysler Town, Dodge Caravan. Manual - part 44

(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

t Dielectric Grease or equivalent.

(5) Repeat the procedure for remaining bushing.

ASSEMBLY - CALIPER PISTON AND SEAL

NOTE: Never use an old 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.
34)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 cock-
ing and binding of the piston.

(4) Install piston into caliper bore pushing it past

the piston seal until it bottoms in the caliper bore
(Fig. 35).

(5) Position the dust boot into the counterbore of

the caliper assembly piston bore.

(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. 36).

(7) Reinstall the caliper on the vehicle and bleed

the brakes as necessary. Refer to Installation in this
section.

Fig. 34 Installing New Piston Seal

1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE

Fig. 35 Installing Piston Into Caliper Bore

1 - BOOT
2 - PISTON
3 - CALIPER

Fig. 36 Installing Dust Boot

1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER

5 - 26

BRAKES - BASE

DISC BRAKE CALIPER - FRONT (Continued)

INSTALLATION

INSTALLATION - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)

CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system (TRW -
disc/drum brake combination and Continental Teves
- disc/disc brake combination). If calipers are inter-
changed,

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 damag-
ing the piston.

CAUTION: Use care when installing the brake cali-
per 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 N·m (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 cal-
iper, 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 N·m (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 N·m (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. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)

(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 - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES)

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 pis-
ton 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 N·m (26 ft. lbs.) (Fig.
32).

(4) Install the banjo bolt connecting the brake hose

to the brake caliper (Fig. 32). 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
N·m (35 ft. lbs.).

(5) Install the tire and wheel assembly. Tighten

the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).

(6) Lower the vehicle.
(7) Remove the brake pedal holding tool.
(8) Bleed the caliper as necessary. (Refer to 5 -

BRAKES - BASE - STANDARD PROCEDURE).

(9) Road test the vehicle and make several stops to

wear off any foreign material on the brakes and to
seat the brake shoes.

DISC BRAKE CALIPER - REAR

REMOVAL - REAR DISC BRAKE CALIPER

NOTE: Handling of the rotor and caliper, must be
done in such a way as to avoid damage to the rotor
and scratching or nicking of lining on the brake
shoes.

BRAKES - BASE

5 - 27

DISC BRAKE CALIPER - FRONT (Continued)

(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 dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir.

(2) Raise the vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(3) Remove rear wheel and tire assembly from

vehicle.

(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 disc brake caliper to adapter guide

pin bolts (Fig. 37).

(6) Remove rear caliper from adapter using the fol-

lowing procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 38).

(7) If the brake rotor requires removal, it can now

be removed by first removing the retainer clips from
the wheel mounting studs, then pulling the rotor
straight off the studs.

DISASSEMBLY - CALIPER PISTON AND SEAL

WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.

NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.

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) Following the removal procedure in DISC

BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle 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 hydrauli-

cally 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 clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.

(4) Mount the caliper in a vise equipped with pro-

tective jaws.

(5) Remove the piston dust boot from the caliper

and discard.

Fig. 37 Caliper Guide Pin Bolts

1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)

Fig. 38 Removing/Installing Caliper

1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER

5 - 28

BRAKES - BASE

DISC BRAKE CALIPER - REAR (Continued)

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.

(6) Using a soft tool such as a plastic trim stick,

work the piston seal out of its groove in caliper pis-
ton bore (Fig. 39). 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 usu-
ally 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 CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET

BRAKE

LININGS.

BREATHING

EXCESSIVE

CONCENTRATIONS

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 CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS

WITH

COMPRESSED AIR

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 CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL 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

t Non-Chlori-

nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids 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 recondi-

tion caliper, replacing the seals and dust boots.

ASSEMBLY - CALIPER PISTON AND SEAL

NOTE: Never use an old 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.
40)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 cock-
ing and binding of the piston.

(4) Install piston into caliper bore pushing it past

the piston seal until it bottoms in the caliper bore
(Fig. 41).

(5) Position the dust boot into the counterbore of

the caliper assembly piston bore.

(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. 42).

Fig. 39 Removing Piston Seal

1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL

BRAKES - BASE

5 - 29

DISC BRAKE CALIPER - REAR (Continued)

Content .. 42 43 44 45 ..