torque CHRYSLER VOYAGER 2002 Repair Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 130 of 2399
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 85
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES..............3
WARNING.............................4
CAUTION..............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................4
STANDARD PROCEDURE - BASE BRAKE
BLEEDING............................7
SPECIFICATIONS
BRAKE FASTENER TORQUE.............9
SPECIAL TOOLS
BASE BRAKE SYSTEM..................9
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................10
ADJUSTABLE PEDAL SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SWITCH.......................11
REMOVAL.............................11
INSTALLATION.........................12
PEDAL POSITION SENSOR
DESCRIPTION.........................12
DIAGNOSIS AND TESTING - PEDAL
POSITION SENSOR....................13
REMOVAL.............................13
INSTALLATION.........................13
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 14
DESCRIPTION - DISC BRAKES (REAR)....15
DESCRIPTION - DISC BRAKES (EXPORT) . . 15DESCRIPTION - DRUM BRAKES (REAR) . . . 16
OPERATION
OPERATION - DISC BRAKES (FRONT).....16
OPERATION - DISC BRAKES (REAR)......16
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................16
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES . 17
OPERATION - BRAKE TUBES AND HOSES . . . 17
INSPECTION - BRAKE TUBES AND HOSES . . . 17
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)..................17
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES).................18
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES.............................19
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DRUM BRAKES)...........19
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....19
CLEANING - DISC BRAKE SHOES..........21
INSPECTION - DISC BRAKE SHOES........21
INSTALLATION - REAR DISC BRAKE SHOES . . 21
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....22
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................25
INSTALLATION - REAR DRUM BRAKE SHOES . 25
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................26
RSBRAKES5-1
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DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)..................26
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES).................26
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........27
DISASSEMBLY - CALIPER PISTON AND
SEAL...............................27
CLEANING - CALIPER...................28
INSPECTION - CALIPER..................28
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........28
ASSEMBLY - CALIPER PISTON AND SEAL . . 28
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DISC BRAKES)...........29
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DRUM BRAKES)..........30
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....30
DISASSEMBLY - CALIPER PISTON AND SEAL . 31
CLEANING - CALIPER...................32
INSPECTION - CALIPER..................32
ASSEMBLY - CALIPER PISTON AND SEAL . . . 32
INSTALLATION - REAR DISC BRAKE CALIPER . 33
DISC BRAKE CALIPER ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER...........................34
INSTALLATION - FRONT DISC BRAKE
CALIPER ADAPTER....................34
DISC BRAKE CALIPER GUIDE PINS
REMOVAL - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES).............34
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (DISC/DRUM BRAKES).......34
DRUM
REMOVAL.............................35
INSTALLATION.........................35
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................35
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................35
SPECIFICATIONS
BRAKE FLUID........................35
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK . 36
OPERATION - NON-ABS JUNCTION BLOCK . . 36
REMOVAL - NON-ABS JUNCTION BLOCK....36
INSTALLATION - NON-ABS JUNCTION BLOCK . 36
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................37DESCRIPTION - RHD..................38
OPERATION...........................38
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................38
REMOVAL
REMOVAL - LHD......................39
REMOVAL - RHD......................40
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................40
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................41
INSTALLATION
INSTALLATION - LHD..................41
INSTALLATION - RHD..................42
PEDAL - ADJUSTABLE
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SYSTEM......................43
REMOVAL.............................43
INSTALLATION.........................45
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................47
INSTALLATION.........................47
POWER BRAKE BOOSTER
DESCRIPTION.........................48
OPERATION...........................49
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................49
REMOVAL
REMOVAL - LHD......................50
REMOVAL - RHD......................52
INSTALLATION
INSTALLATION - LHD..................53
INSTALLATION - RHD..................55
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................56
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................57
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................57
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................58
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................59
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 59
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................61
REMOVAL - FRONT BRAKE ROTOR........62
INSTALLATION - FRONT BRAKE ROTOR.....62
SPECIFICATIONS
BRAKE ROTOR.......................63
BRAKE ROTOR - EXPORT..............63
5 - 2 BRAKES - BASERS
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Page 138 of 2399
(6) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
ABS ICU Mounting Bolts To
Bracket11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts28 21 250
ABS CAB-To-HCU Mounting
Screws2Ð17
ABS Wheel Speed Sensor
Head Mounting Bolt - Front13 Ð 115
ABS Wheel Speed Sensor
Head Mounting Bolt - Rear10 Ð 90
Adjustable Pedal Position
Sensor Mounting Screws7.5 66 Ð
Adjustable Pedal Module
Mounting Screws2.0 15 Ð
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt47 35 Ð
Disc Brake Caliper Guide
Pin Bolts35 26 Ð
Disc Brake Caliper Bleeder
Screw15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw10 Ð 80
Drum Brake Support Plate
Mounting Bolts130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts28 21 250
Master Cylinder Mounting
Nuts25 19 225
Power Brake Booster
Mounting Nuts28 21 250
Proportioning Valve
Mounting Bolts54 40 Ð
Proportioning Valve Axle
Bracket Mounting Bolt20 Ð 175
Parking Brake Lever (Pedal)
Mounting Bolts And Nut28 21 250
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
BASE BRAKE SYSTEM
Fig. 3 TOOL 6921 INSTALLED ON MASTER
CYLINDER
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
Tubes, Master Cylinder Bleeding 6920
RSBRAKES - BASE5-9
BRAKES - BASE (Continued)
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Page 142 of 2399
DIAGNOSIS AND TESTING - PEDAL POSITION
SENSOR
Refer to Appropriate Diagnostic Information.
REMOVAL
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Press release tab to the left (Fig. 11), then
remove bulkhead connector from bracket by pulling it
toward lower steering column cover.(4) Move bulkhead connector toward left side of
vehicle as far as its wires will allow. Do not over-
stress wiring.
(5) Remove two mounting screws securing pedal
position sensor in place (Fig. 12).
(6) Remove pedal position sensor from bracket.
(7) Disconnect wiring connector and remove pedal
position sensor.
INSTALLATION
(1) Connect wiring connector to pedal position sen-
sor.
NOTE: Make sure pin in pedal assembly fits into
slot in sensor carriage when installing sensor.
(2) Place sensor against mounting bracket and into
brake pedal (Fig. 12). Move carriage as necessary to
align slot with pin. Install two mounting screws.
Tighten screws to 7.5 N´m (66 in. lbs.) torque.
(3) Align the bulkhead connector mounting slot
with its bracket and install it, locking it in place.
(4) Install silencer panel below lower steering col-
umn cover.
(5) Connect ground cable to negative post of bat-
tery.
(6) Connect scan tool (DRBIIIt) to data link diag-
nostic connector located below steering column.
(7) Turn ignition key to ON position.
(8) Using scan tool, check for and clear any exist-
ing adjustable pedal fault codes.
(9) Test operation of adjustable pedals, memory
sets (if equipped), and RKE (if equipped). If applica-
ble, reset radio and clock.
(10) Recheck for any fault codes.
Fig. 10 Pedal Position Sensor Location
1 - PEDAL POSITION SENSOR
2 - BRAKE PEDAL
Fig. 11 Bulkhead Connector Release Tab
1 - RELEASE TAB
2 - PEDAL POSITION SENSOR
3 - BULKHEAD CONNECTOR
Fig. 12 Pedal Position Sensor
1 - WIRING CONNECTOR
2 - GEAR BOX
3 - PEDAL POSITION SENSOR
RSBRAKES - BASE5-13
PEDAL POSITION SENSOR (Continued)
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Page 148 of 2399
Replacebothdisc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were removed from.
INSTALLATION
INSTALLATION - FRONT DISC BRAKE SHOES
NOTE: There may be more than 1 lining material
released. Make sure proper linings are being
installed.
(1) Begin on one side of the vehicle or the other.
(2) Completely retract the caliper piston back into
its bore in the brake caliper (This is required for cal-
iper installation on the brake rotor with new brake
shoes installed).
(3) If applied, remove the protective paper from
the noise suppression gasket on the rear of both the
inner and outer brake shoe assemblies.
(4) Install the new inboard brake shoe into the cal-
iper piston by firmly pressing its retaining clip into
the piston bore. Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Lubricate both adapter abutments where the
shoes slide with a small amount of MopartDielectric
grease, or equivalent.
(6) Slide the new outboard brake shoe into the cal-
iper adapter with the lining up against the outside of
the brake rotor.
CAUTION: Use care when installing the caliper
assembly onto the caliper adapter, so the caliper
guide pin bushings do not get damaged by the
adapter bosses.
(7) Carefully position the brake caliper over the
brake rotor and adapter.
(8) 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.
(9) Install the caps over the caliper guide pin bolts.
(10) Install the new caliper hold down spring (anti-
rattle clip) on the outboard side of the caliper. Start
the spring into the holes on the caliper, then stretch
the clip legs past the abutments on the caliper
adapter.
(11) Repeat the above procedure on other side of
the vehicle.(12) Install the wheel and tire assemblies. Tighten
the wheel mounting 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.).
(13) Lower vehicle.
(14) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(15) Check and adjust brake fluid level as neces-
sary.
(16) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
NOTE: Perform steps Step 1 through Step 5on each
side of the vehicle.
(1) Place the brake shoes in the adapter anti-rattle
clips.
(2) Completely retract the caliper piston back into
the bore of the caliper.
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.
(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 N´m (26 ft. lbs.) (Fig.
22).
(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) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(8) Check and adjust the brake fluid level as nec-
essary.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE PADS/SHOES - REAR
DISC
REMOVAL - REAR DISC BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
RSBRAKES - BASE5-19
BRAKE PADS/SHOES - FRONT (Continued)
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Page 151 of 2399
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
(8) Install the wheel and tire assembly. Tighten
the wheel mounting 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.).
(9) Lower vehicle.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(10) Pump brake pedal several times to set brake
shoes to rotors.
(11) Check fluid level in reservoir.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
BRAKE PADS/SHOES - REAR
DRUM
REMOVAL - REAR DRUM BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM
- REMOVAL)
NOTE: When creating slack in the park brake cables
by locking out the automatic adjuster, (Fig. 27) be
sure that the park brake pedal is in the released
(most upward) position.(4) Create slack in the rear park brake cables.
Slack is created by grabbing exposed section of front
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake
cable just rearward ofonly the rearbody outrigger
bracket. (Fig. 27)
(5) Remove adjustment lever spring (Fig. 28) from
adjustment lever and front brake shoe.
Fig. 27 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 28 Adjustment Lever Actuating Spring
1 - TRAILING BRAKE SHOE
2 - LEADING BRAKE SHOE
3 - AUTOMATIC ADJUSTER LEVER
4 - ADJUSTER LEVER ACTUATING SPRING
5 - 22 BRAKES - BASERS
BRAKE PADS/SHOES - REAR DISC (Continued)
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Page 155 of 2399
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 32). If
it is located on a non-threaded area of the adjuster,
the function of the automatic adjuster will be
affected.
(7) Install the tension clip (Fig. 32) attaching the
upper return spring to the automatic adjuster assem-
bly.
(8) Install the brake shoe to brake shoe lower
return springs on the brake shoes (Fig. 30) and (Fig.
31).
(9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 29).
(10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 28).
(11) Verify that the automatic adjuster lever has
positive contact with the star wheel on the automatic
adjuster assembly.
(12) When all components of both rear brake
assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
(13) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(14) Install the rear brake drums on the hubs.
(15) Adjust rear brake shoes.
(16) Install the wheel and tire assembly.
(17) 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.).
(18) Lower the vehicle.
(19) Push the parking brake lever (pedal) to the
floor once and release pedal. This will automatically
remove the slack from and correctly adjust the park-
ing brake cables.
(20) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE SHOES
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
NOTE: Before raising the vehicle, verify the parking
brake lever is fully released.(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove rubber plug from rear brake adjusting
hole in the rear brake support plate.
(3) Insert a thin screwdriver through the adjusting
hole in the support plate and against the star wheel
of the adjusting screw. Move handle of the tool
upward rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated.
(4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel.Care should be taken so as not to bend
adjusting lever or distort lever spring.
(5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag.
(6) Repeat the above adjustment at the other rear
wheel.
(7) Install the adjusting hole rubber plugs back in
the rear brake support plates.
(8) Lower the vehicle.
DISC BRAKE CALIPER -
FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)
(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 front wheel and tire assembly.
(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 2 caliper guide pin bolts.
(6) Remove the brake caliper from the adapter.
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES)
(1) Using a brake pedal holding tool, depress the
brake pedal past its first one inch of travel and hold
it in this position. This will isolate the master cylin-
der from the brake hydraulic system and will not
5 - 26 BRAKES - BASERS
BRAKE PADS/SHOES - REAR DRUM (Continued)
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Page 158 of 2399
(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. 44).
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
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
Fig. 42 Installing New Piston Seal
1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
Fig. 43 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 44 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
RSBRAKES - BASE5-29
DISC BRAKE CALIPER - FRONT (Continued)
ProCarManuals.com
Page 159 of 2399
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)
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
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.
40).
(4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 40). 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.
(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. 45).
(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. 46).
(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.
5 - 30 BRAKES - BASERS
DISC BRAKE CALIPER - FRONT (Continued)
ProCarManuals.com
Page 162 of 2399
(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. 50).
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
INSTALLATION - REAR DISC BRAKE CALIPER
(1) Completely retract caliper piston back into pis-
ton bore of the caliper.
(2) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(3) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 46).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to cross-thread the cal-
iper guide pin bolts.
(4) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special copper 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.
(7) 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.).
(8) Lower the vehicle.
(9) Remove the brake pedal depressor (holding)
tool.
(10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)
(11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
Fig. 49 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 50 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
RSBRAKES - BASE5-33
DISC BRAKE CALIPER - REAR (Continued)
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