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Fig. 5 Disc Brake Caliper Mounting (Typical)

SHOE AND LINING WEAR

If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers.

Fig. 6 Piston Seal Function for Automatic Adjustment

Remove the shoe and lining assemblies. (See Brake Shoe Removal paragraph).

Combined shoe and lining thickness should be measured at the thinnest part of the assembly.

When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (5/16 inch) it should be replaced.

Replace both shoe assemblies (inboard and outboard) on the front wheels. It is necessary that both front wheel sets be replaced whenever shoe assemblies on either side are replaced.

If a shoe assembly does not require replacement. Reinstall, the shoe assemblies making sure each shoe assembly is returned to the original position. (See Brake Shoe Installation).

5 - 34 BRAKES

SERVICE PRECAUTIONS

WARNING: DUST AND DIRT ON BRAKE PARTS GENERATED DURING THE NORMAL USE AND WEAR OF MOTOR VEHICLE BRAKE SYSTEMS CAN CONTAIN ASBESTOS FIBERS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM, SUCH AS ASBESTOSIS AND CANCER. EXTREME CARE SHOULD BE EXERCISED WHILE SERVICING BRAKE ASSEMBLIES OR COMPONENTS.

DO NOT CLEAN BRAKE ASSEMBLIES OR COMPONENTS WITH COMPRESSED AIR OR BY DRY BRUSHING; USE A VACUUM CLEANER SPECIFICALLY RECOMMENDED FOR USE WITH ASBESTOS FIBERS. IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET USING A WATER DAMPENED CLOTH.

DO NOT CREATE DUST BY SANDING, GRINDING, AND/OR SHAVING BRAKE LININGS OR PADS UNLESS SUCH OPERATION IS DONE WHILE USING PROPERLY EXHAUST VENTILATED EQUIPMENT.

DISPOSE OF ALL DUST AND DIRT SUSPECTED TO CONTAIN ANY ASBESTOS FIBERS IN SEALED

Ä

BAGS OR CONTAINERS TO MINIMIZE DUST EXPOSURE TO YOURSELF AND OTHERS.

FOLLOW ALL RECOMMENDED PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION AND THE ENVIRONMENTAL PROTECTION AGENCY. FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST OR DIRT WHICH MAY CONTAIN ASBESTOS FIBERS.

Grease or any other foreign material must be kept off the caliper assembly, surfaces of the braking disc and external surfaces of the hub, during service procedures.

Handling of the braking disc and caliper. Should be done in such a way as to avoid deformation of the disc and scratching or nicking of the brake linings.

If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately.

During removal and installation of a wheel and tire assembly, use care not to strike the caliper.

Before vehicle is moved after any brake service work, be sure to obtain a firm brake pedal.

Fig. 1 Removing or Installing Caliper Guide Pin Bolts

(4)After removing the caliper guide pin bolts. Pry the caliper away from the braking disc with a pry bar or screwdriver (Fig. 2).

(5)Remove caliper assembly from braking disc and adapter by sliding the assembly out and away from the braking disc and adapter (Fig. 3).

(6)Support caliper firmly to prevent weight of caliper from damaging the flexible brake hose (Fig. 4).

(7)Remove the outboard brake shoe assembly from the caliper adapter (Fig. 5).

(8)Remove the braking disk (rotor) from the hub by pulling it straight off the wheel mounting studs (Fig. 6).

(9)Remove the inboard brake shoe assembly by sliding it out along the bottom adapter abutment until brake shoe assembly loosens from anti-rattle clip (Fig. 7).

(10)Remove the anti-rattle clip from the top adapter abutment (Fig. 8).

Fig. 2 Loosening Family Caliper Assembly From

Adapter And Rotor

Fig. 3 Removing or Installing Caliper Assembly

Fig. 4 Storing Caliper

Fig. 5 Removing and Installing Outboard Shoe As-

sembly

INSTALLATION

(1)Lubricate both adapter abutments with a liberal amount of Mopart Multipurpose Lubricant, or equivalent.

(2)Install the anti-rattle clip on the upper abutment of the caliper mounting adapter (Fig. 8).

(3)Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped).

Fig. 6 Removing or Installing Braking Disc

Fig. 7 Removing or Installing Inboard Shoe Assembly

(4)Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter abutments. Be careful not to get any grease from the adapter abutment on the surface of the brake lining material, (Fig. 7). Be sure inboard brake shoe assembly is correctly positioned against anti-rattle clip (Fig. 6).

(5)Reinstall the Braking Disk on the hub, by installing it over the wheel studs until it is seated against the face of the hub (Fig. 6).

Fig. 8 Remove Or Replace Anti-Rattle Clip

(6)Slide the new outboard brake shoe assembly on the adapter abutment, (Fig. 5).

(7)Carefully lower caliper over the braking disk and brake shoe assemblies (Fig. 3). Make sure that the caliper guide pin bolt, bushings and sleeves are clear of the adapter.

(8)Install the caliper guide pin bolts and tighten to 34 to 37 NIm (25 to 35 ft. lbs.). Extreme caution should be taken not to cross the threads of the caliper guide pin bolts.

Fig. 9 Tightening Wheel Nuts

(9)Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence (Fig. 9) until all nuts are torqued to half specification. This is

important. Then repeat the tightening sequence to the full specified torque of 129 NIm (95 ft. lbs.).

(10)Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle..

Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.

SERVICE PROCEDURES

BRAKE SHOES REMOVE

Raise the vehicle on jackstands or centered on a hoist. Remove the front wheel and tire assemblies from

the vehicle.

Remove the brake caliper assembly to steering knuckle attaching guide pin bolts (Fig. 1).

Pull lower end of brake caliper out from the machined abutment on the steering knuckle (Fig. 2). Then roll caliper out and away from braking disc (Fig. 2). The brake shoe assemblies will remain with the brake caliper.

When the caliper is removed from the vehicle to service the brake shoes. SUPPORT CALIPER

FIRMLY TO PREVENT WEIGHT OF CALIPER FROM DAMAGING THE FLEXIBLE HOSE. (See Fig. 3.)

Remove the outboard brake shoe by prying between the top of the outboard shoe and the top of the caliper assembly as shown in (Fig. 4).

Remove the inboard brake shoe from the caliper, by pulling the inboard shoe assembly away from the piston (Fig. 5).

Fig. 2 Removing Caliper and Brake Shoes as an

Assembly

Fig. 3 Storing Caliper

Fig. 4 Prying Outboard Shoe Assembly Away from Caliper

CLEANING AND INSPECTION

Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot,(and piston if scored). Refer to procedures titled DISC BRAKE CALIPER DISASSEMBLY.

Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Caliper Service.

Fig. 5 Removing or Installing Inboard Shoe Assembly

BRAKE SHOES INSTALL

Lubricate both adapter ways on the steering knuckle, with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.

The inboard brake shoes are common. The outboard brake shoes are marked with an (LH) or (RH) to denote which side of the vehicle to be installed on (Fig. 6).

Fig. 6 Brake Shoe Identification

Install new inboard brake shoe assembly in caliper, by installing retaining clip into the bore of the piston (Fig. 5).