Disassembly and Assembly
Fig 6 Outboard Brake Shoe Removal/Installation:
Fig 7 Inboard Brake Shoe Removal/Installation:
CALIPER DISASSEMBLY
1. Remove brake shoes from caliper. Discard shoes if worn, or damaged.
2. Drain old brake fluid out of caliper into drain pan.
Piston Dust Boot:
3. Remove piston dust boot. Use screwdriver to push boot out of groove.
Caliper Piston Removal:
4. Pad outboard shoe side of caliper interior with a minimum 2.54 cm (1 in.) thickness of shop towels. Towels will prevent piston damage when piston is comes out of bore.
5. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper.
Caliper Piston Seal:
CAUTION: Do not blow the piston out of the caliper. This procedure will usually result In severe piston damage. Use only enough air pressure to ease the piston out of the bore. In, addition, never attempt to catch the piston as it leaves the caliper bore. This practice will result in personal injury.
6. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore.
Fig 18 Disc Brake Caliper Components -- 2WD:
7. Remove caliper slide pin bushings and boots.
CALIPER CLEANING AND INSPECTION
Clean the caliper and piston with clean brake fluid or Mopar brake cleaning solvent only. Do not use gasoline, kerosene, thinner, or any similar type of solvent. These products will leave a residue that could damage the piston, seal, or piston bore.
Wipe the caliper and piston dry with lint free, towels or use low pressure compressed air.
Inspect the piston and piston bore. Replace the caliper if the bore is corroded, rusted, or scored. Do not hone the caliper piston bore. Replace the caliper if the bore is damaged.
Inspect the caliper piston. The piston is made from a phenolic resin (plastic material) and should be smooth and clean. Replace the piston if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. The piston must be replaced if damaged.
CAUTION: If the caliper piston must be replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bores and piston tolerances are different for resin and steel pistons and calipers. Do not intermix these components at any time.
Inspect the caliper bushings and boots. Replace the boots if cut or torn. Clean and relubricate the bushings with GE 661, Dow 111, or similar silicone grease if necessary.
CALIPER ASSEMBLY
1. Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install boots and bushings in caliper.
2. Coat caliper piston bore, piston and new piston seal with fresh brake fluid.
Fig 19 Installing Caliper Piston Seal:
3. Install new piston seal in caliper bore. Press F seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation.
4. Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of caliper piston and edge of dust boot.
Sliding Boot Onto Piston:
5. Install new dust boot on caliper piston as follow:
a. Slide boot over piston until boot lip seats in piston groove.
Snapping Boot Folds Into Place:
b. Push retainer part of boot forward until folds in boot snap into place.
Fig 22 Installing Caliper Piston And Boot:
6. Start caliper piston into bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it.
7. Press caliper piston to bottom of bore.
Fig 23 Seating Piston Dust Boot:
8. Seat piston dust boot with Installer Tool 7868, or C-4842 and Tool Handle C-4171.
Caliper Bleed Screw & Cap Installation:
9. Install caliper bleed screw and bleed screw cap if removed.