Chrysler PT Cruiser. Manual — part 419

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

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(3) Remove the rear tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake

hose to the brake caliper (Fig. 43). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Discard the
washers.

NOTE: In some cases, it may be necessary to
retract the caliper piston in its bore a small amount
in order to provide sufficient clearance between the
shoes and the rotor to easily remove the caliper
from the knuckle. This can usually be accomplished
before the guide pin bolts are removed, by grasping
the rear of the caliper and pulling outward working
with the guide pins, thus retracting the piston.

Never push on the piston directly as it may get
damaged.

(5) Remove the two caliper guide pin bolts (Fig.

44).

(6) Remove the caliper assembly from the brake

adapter by first rotating the top of the caliper away
from the rotor, and then lifting the caliper assembly
off the machined abutment on the adapter (Fig. 45).

Fig. 42 Brake Pedal Holding Tool

Fig. 43 Brake Hose Mounting

1 - BANJO BOLT
2 - GUIDE PIN BOLTS
3 - CALIPER
4 - BRAKE HOSE

Fig. 44 Caliper Mounting

1 - DISC BRAKE ADAPTER
2 - GUIDE PIN BOLTS
3 - HUB AND BEARING
4 - BRAKE ROTOR
5 - RETAINER CLIP
6 - DUST CAP
7 - NUT
8 - DISC BRAKE CALIPER

Fig. 45 Removing Caliper From Adapter

1 - BRAKING DISC
2 - CALIPER ADAPTER
3 - CALIPER
4 - LOWER MACHINED ADAPTER ABUTMENT

5 - 28

BRAKES - BASE

PT

DISC BRAKE CALIPER - REAR (Continued)

DISASSEMBLY

DISASSEMBLY - DISC BRAKE CALIPER (GUIDE
PIN BUSHINGS)

Before disassembling the brake caliper, clean and

inspect it. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSPEC-
TION).

(1) With one hand, push the guide pin bushing

sleeve towards the back of the caliper, and at the
same time, pull the sleeve out the back of the caliper
and bushing (Fig. 46).

(2) Using your fingers, collapse one side of the rub-

ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss
(Fig. 47).

DISASSEMBLY - DISC BRAKE CALIPER
(PISTON AND SEAL)

Before disassembling the brake caliper, clean and

inspect it. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSPEC-
TION).

CALIPER PISTON REMOVAL

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: 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 (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - REMOVAL),
remove the caliper from the brake rotor and hang the
assembly on a wire hook away from rotor and body of
the vehicle so brake fluid cannot get on these compo-
nents. 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.

CALIPER SEAL REMOVAL

CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.

Fig. 46 Removing Sleeve From Bushing

1 - CALIPER
2 - SLEEVE
3 - BUSHING

Fig. 47 Removing Bushing From Caliper

1 - CALIPER
2 - BUSHING

PT

BRAKES - BASE

5 - 29

DISC BRAKE CALIPER - REAR (Continued)

(1) To disassemble the caliper, mount it in a vise

equipped with protective jaws.

(2) Remove the piston dust boot from the caliper

and discard (Fig. 48).

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.

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

work the piston seal out of its groove in caliper pis-
ton bore (Fig. 49). Discard the old seal.

(4) Clean the piston bore and drilled passage ways

using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.

(5) 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. Bores that have deep scratches or
scoring should be honed. Use Caliper Hone, Special
Tool C-4095, or the equivalent to hone the bore. Do
not over-hone the bore. Don not increase the diame-
ter of the bore more than 0.0254 mm (0.001 inch)
(Fig. 50). If the bore does not clean up within this
specification,

a

new

caliper

housing

should

be

installed.

NOTE: During the honing procedure, coat the
stones and bore with brake fluid. After honing the
bore, carefully clean the seal and boot grooves with
a stiff non-metallic rotary brush. Use extreme care

in cleaning the caliper after honing. Remove all dirt
and grit by flushing the caliper bore with fresh
clean brake fluid; wipe it dry with a clean, lint free
cloth and then clean it a second time.

Fig. 48 Removing Caliper/Piston Dust Boot

1 - CALIPER
2 - SCREWDRIVER
3 - BOOT

Fig. 49 Removing Piston Seal

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

Fig. 50 Honing Brake Caliper Piston Bore

1 - CALIPER
2 - CALIPER BORE
3 - SPECIAL TOOL C-4095

5 - 30

BRAKES - BASE

PT

DISC BRAKE CALIPER - REAR (Continued)

(6) Inspect the caliper piston for pitting, scratches,

or any physical damage. Replace the piston if there is
evidence of scratches, pitting or physical damage.

CLEANING - DISC BRAKE 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

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 CON-
TAIN 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 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 - DISC BRAKE 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

ASSEMBLY - DISC BRAKE CALIPER (GUIDE
PIN BUSHINGS)

(1) Fold the guide pin bushing in half lengthwise

at the solid middle section (Fig. 51).

NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.

(2) Insert the folded bushing into the caliper

mounting boss using your fingers (Fig. 52).

(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 (Fig.
53).

Fig. 51 Folded Caliper Guide Pin Bushing

1 - CALIPER GUIDE PIN BUSHING

Fig. 52 Installing Caliper Guide Pin Bushing

1 - CALIPER
2 - BUSHING

PT

BRAKES - BASE

5 - 31

DISC BRAKE CALIPER - REAR (Continued)