Front Disc Brake Caliper
DISC BRAKE CALIPER - FRONT - SRT-4REMOVAL
NOTE: Before proceeding, Refer to WARNING/CAUTION.
1. Using a brake pedal holding tool, depress the brake pedal past its first one inch of travel and secure 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. 62). 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. 62).
6. Remove the disc brake caliper from the disc brake adapter.
DISASSEMBLY
NOTE: Before disassembling the brake caliper, remove it from the vehicle, 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.
2. Place a wooden block in the caliper as shown (Fig. 63).
WARNING: DO NOT PLACE FACE OR HANDS NEAR CALIPER AND PISTON IF USING COMPRESSED AIR PRESSURE TO REMOVE PISTON. DO NOT USE HIGH PRESSURE.
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.
5. Remove the dust boot from the piston and discard it.
CAUTION: 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 piston bore (Fig. 64). Discard the old seal.
7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
8. Inspect both the piston and 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 - DISC BRAKE 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 - DISC BRAKE CALIPER
Inspect the disc brake caliper for the following:
^ Brake fluid leaks in and around piston 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.
ASSEMBLY
NOTE: Always use new, clean Mopar DOT 3 brake fluid when assembling the brake caliper. 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 (Fig. 65). The seal should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it.
2. Coat the new piston with clean brake fluid.
3. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot.
4. Position the dust boot over the lower section of the piston (Fig. 66).
5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
6. Install the piston into the bore carefully pushing it past the piston seal using hand pressure (Fig. 67). Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston.
7. Reinstall 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 BR3 Performance Brake System must not be mixed with other brake systems. These parts can be easily identified.
1. Completely retract the caliper piston back into the 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.
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. Make sure the springs on the shoes do not get caught in the hole formed into the center of the caliper housing.
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. 62).
4. Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 62). 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 a torque of 24 Nm (210 inch 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.
DISC BRAKE CALIPER GUIDE PINS - FRONT - SRT-4
REMOVAL
NOTE: Before proceeding, Refer to WARNING/CAUTION.
1. Raise the vehicle.
2. Remove the front tire and wheel assembly.
3. Remove the two brake caliper guide pin bolts (Fig. 68).
4. Remove the disc brake caliper from the disc brake caliper adapter and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.
5. Remove the guide pins and boots from the adapter as shown (Fig. 69).
INSTALLATION
1. Lubricate the guide pins and inside the boots with the packet supplied with the service kit, Sythesco GLK-1 lubricant or equivalent.
2. Install the guide pins and boots in the adapter as shown (Fig. 69). The boots have grooves built into their inner lips to fit onto the pins and adapter.
CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins.
3. Install the disc brake caliper over the brake shoes on the brake caliper adapter. Make sure the springs on the shoes do not get caught in the hole formed into the center of the caliper housing.
4. 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. 68).
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. Pump the brake pedal several times before moving the vehicle to set the shoes to the brake rotor.