Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 222
(5) Clamp caliper in vise (with protective caps on
vise jaws).
(6) Remove dust boot from the brake caliper and
discard (Fig. 1).
(7) Using a plastic trim stick, work piston seal out of
its groove in caliper piston bore (Fig. 2). Discard old
seal. Do not use a screwdriver or other metal tool
for this operation, because of the possibility of
scratching piston bore or burring edges of seal
groove.
The double pin caliper uses a sealed for life bushing
and sleeve assembly. If required this assembly can be
serviced using the following procedure.
(1) Push out and then pull the inner sleeve from
inside of the bushing using your fingers as shown in
(Fig. 3)
(2) Using your fingers collapse one side of the bush-
ing. Then pull on the opposite side to remove the
bushing from the brake caliper assembly (Fig. 4).
CLEANING AND INSPECTION OF BRAKE CALIPER
Clean all parts using alcohol or a suitable solvent
and wipe dry using only a lint free cloth, no lint
residue can remain in caliper bore. Clean out all drilled
passages and bores. (Whenever a caliper has been
disassembled, a new boot and seal must be in-
stalled at assembly).
Inspect the piston bore for scoring or pitting. Bores
that show light scratches or corrosion, can usually 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
equivalent providing the diameter of the bore is not
increased more than 0.0254 mm (0.001 inch) (Fig. 5).
If the bore does not clean up within this specification,
a new caliper housing should be installed. Install a new
piston if the old one is pitted or scored.
When using Caliper Honing Tool, Special Tool
C-4095, 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.
Fig. 1 Removing Piston Dust Boot
Fig. 2 Removing Piston Seal
Fig. 3 Removing Inner Sleeve
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Use extreme care in cleaning the caliper after
honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean,
lint free cloth and then clean a second time.
ASSEMBLING DISC BRAKE CALIPER
Clamp caliper in vise (with protective caps on vise
jaws).
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
Dip new piston seal in clean brake fluid and install
in the groove of the caliper bore. Seal should be po-
sitioned at one area in groove and gently worked
around the groove (Fig. 1), using only your fingers
until properly seated.
NEVER USE AN OLD PISTON SEAL. (Be sure
that fingers are clean and seal is not twisted or
rolled) (Fig. 1).
Coat new piston boot with clean brake fluid leav-
ing a generous amount inside boot.
Position dust boot over piston after coating with
brake fluid.
Install piston into caliper bore pushing it past the
piston seal until it bottoms in the caliper bore (Fig.
2).
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
Fig. 1 Installing New Piston Seal
Fig. 2 Pushing Piston into Bore
Fig. 4 Removing Bushings From Caliper
Fig. 5 Honing Piston Bore
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BRAKES
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Position dust boot in counterbore of the caliper piston
bore.
Using a hammer and Installer Piston Caliper Boot,
Special Tool C-4689 and Handle, Special Tool C-4171,
drive boot into counterbore of the caliper (Fig. 3).
Use the following steps, to install the Guide Pin
Sleeve Bushings into the caliper assembly.
(1) Fold the bushing in half lengthwise at the solid
middle section of the bushing (Fig. 4).
(2) Using your fingers insert the folded bushing into
the caliper assembly (Fig. 5). Do not use a sharp
object to perform this step do to possible damage
to the bushing.
(3) Unfold the bushing using your fingers or a
wooden dowel until the bushing is fully seated into
the caliper assembly. Flanges should be seated
evenly on both sides of the bushing hole in the cali-
per assembly (Fig. 6).
Install the Guide Pin Sleeve into the guide bushing
using the following procedure.
(1) Install the sleeve into one end of the bushing
until the seal area of the bushing is past the seal
groove in the sleeve (Fig. 7).
(2) Holding the convoluted end of the bushing with
one hand. Push the sleeve through the bushing (Fig.
Fig. 5 Installing Caliper Guide Pin Sleeve Bushings
Fig. 6 Bushing Correctly Installed In Caliper
Fig. 3 Installing Dust Boot in Caliper Counterbore
Fig. 4 Folded Caliper Guide Pin Bushing
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7) until the one end of the bushing is fully seated
into the seal groove on the one end of the sleeve.
(3) Holding the sleeve in place work the other end
of the bushing over the end of the sleeve and into the
seal grove (Fig. 8). Be sure the other end of the bush-
ing did not come out of the seal grove in the sleeve.
(4) When the sleeve is seated properly into the
bushing. The sealed for life bushing can be held be-
tween your fingers and easily slid back and forth
without the bushing seal unseating from the sleeve.
Before installing caliper assembly on vehicle, inspect
braking disc. If any conditions as described in Check-
ing Braking Disc for Runout and Thickness are present
the braking disc, must be replaced or refaced. If the
braking disc does not require any servicing, install
caliper assembly.
Install brake hose onto caliper using banjo bolt.
Torque the brake hose to caliper assembly banjo bolt to
33 N
Im (24 ft. lbs.). New seal washers MUST al-
ways be used when installing brake hose to cali-
per.
Bleed the brake system (see Bleeding Brake System).
Fig. 7 Installing Caliper Sleeves
Fig. 8 Installed Caliper Bushing Sleeve
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BRAKES
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