Chrysler RG Voyager. Manual — part 654

CLEANING - 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 - 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 - CALIPER PISTON AND SEAL

NOTE: 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. The
seal should be started at one area of the groove and
gently worked around and into the groove (Fig.
39)using only your clean fingers to seat it.

(2) Coat the new piston boot with clean brake

fluid.

(3) Position the dust boot over the piston after

coating it with brake fluid.

CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.

(4) Install piston into caliper bore pushing it past

the piston seal until it bottoms in the caliper bore
(Fig. 40).

(5) Position the dust boot into the counterbore of

the caliper assembly piston bore.

Fig. 38 Removing Piston Seal

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

Fig. 39 Installing New Piston Seal

1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE

RS

BRAKES - BASE

5 - 29

DISC BRAKE CALIPER - REAR (Continued)

(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. 41).

(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. 37).

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. 40 Installing Piston Into Caliper Bore

1 - BOOT
2 - PISTON
3 - CALIPER

Fig. 41 Installing Dust Boot

1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER

5 - 30

BRAKES - BASE

RS

DISC BRAKE CALIPER - REAR (Continued)

DISC BRAKE CALIPER
ADAPTER

REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER

(1) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(2) Remove front wheel and tire assembly, disc

brake caliper and brake shoes. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL)

(3) Remove two bolts fastening adapter to steering

knuckle, then remove disc brake caliper adapter.

INSTALLATION - FRONT DISC BRAKE CALIPER
ADAPTER

(1) Place adapter over brake rotor and align

adapter mounting holes to knuckle.

CAUTION: Adapter mounting bolts have a special
Dacromet

T

coating applied to resist corrosion. If

mounting bolts need to be replaced, use only
Mopar

T

replacement parts.

(2) Install adapter mounting bolts and tighten to

169 N·m (125 ft. lbs.) torque.

(3) Install brake shoes, disc brake caliper and

wheel and tire assembly. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE

PADS/SHOES

-

INSTALLATION)

(4) Lower vehicle.
(5) Pump the brake pedal several times to set the

pads to the brake rotor.

(6) Check and adjust brake fluid level as neces-

sary.

DISC BRAKE CALIPER GUIDE
PINS

REMOVAL - DISC BRAKE CALIPER GUIDE PINS
(TRW BRAKES)

(1) Raise the vehicle. Refer to HOISTING in

LUBRICATION AND MAINTENANCE.

(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts

(Fig. 42).

(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 overex-
tend the brake hose when doing this.

(5) Remove the guide pins and boots from the

adapter as shown (Fig. 43).

INSTALLATION - DISC BRAKE CALIPER GUIDE
PINS (TRW BRAKES)

(1) Lubricate the guide pins and inside the boots

with the packet supplied with the service kit, Syth-
eso GLK-1 lubricant or equivalent.

(2) Install the guide pins and boots in the adapter

as shown (Fig. 43). 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.

Fig. 42 Brake Caliper Mounting

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

Fig. 43 Guide Pins And Boots

1 - PINS
2 - BOOTS

RS

BRAKES - BASE

5 - 31

(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.
42).

(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 before

moving the vehicle to set the shoes to the brake
rotor.

DRUM

REMOVAL

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

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove the tire and wheel assembly from the

vehicle

(3) Remove the rear brake shoe adjusting hole

cover plug.

(4) Insert a thin screwdriver into brake adjusting

hole and hold adjusting lever away from notches of
adjusting screw star wheel.

(5) Insert another thin screwdriver into brake

adjusting hole and engage notches of brake adjusting
screw star wheel. Release brake adjustment by pry-
ing upward with adjusting tool.

(6) Remove rear brake drum from rear hub/bear-

ing assembly.

NOTE: It may be necessary to insert M8 X 1.25 MM
bolts into the two removal holes on the drum to
force the drum off the hub.

INSTALLATION

(1) Adjust brake shoe assemblies so as not to inter-

fere with brake drum installation.

(2) Install the rear brake drums on the hubs.
(3) Adjust drum brake shoes as necessary per pro-

cedure found in the Adjustment section of this ser-
vice

manual

group

(Refer

to

5

-

BRAKES/

HYDRAULIC/MECHANICAL/DRUM

-

ADJUSTMENTS).

(4) Install wheel and tire assembly.
(5) 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.).

(6) Lower the vehicle.

FLUID

DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION

Indications of fluid contamination are swollen or

deteriorated rubber parts.

Swollen rubber parts indicate the presence of

petroleum in the brake fluid.

To test for contamination, put a small amount of

drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.

If brake fluid is contaminated, drain and thor-

oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brake hydraulic unit and all hydraulic fluid
hoses.

STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING

Check master cylinder reservoir fluid level a mini-

mum of twice annually.

Fluid reservoirs are marked with the words FULL

and ADD to indicate proper brake fluid fill level of
the master cylinder.

If necessary, add brake fluid to bring the level to

the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.

Use only Mopar

t brake fluid or equivalent from a

sealed container. Brake fluid must conform to DOT 3
specifications.

DO NOT use brake fluid with a lower boiling

point, as brake failure could result during prolonged
hard braking.

Use only brake fluid that was stored in a tightly-

sealed container.

DO NOT use petroleum-based fluid because seal

damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.

SPECIFICATIONS

BRAKE FLUID

The brake fluid used in this vehicle must conform

to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar

t Brake Fluid or equivalent from a tightly

sealed container.

CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.

5 - 32

BRAKES - BASE

RS

DISC BRAKE CALIPER GUIDE PINS (Continued)