Chrysler Pacifica. Manual — part 450

WARNING: DO NOT PLACE FACE OR HANDS NEAR
CALIPER AND PISTON IF USING COMPRESSED AIR
TO REMOVE PISTON. DO NOT USE HIGH PRES-
SURE.

WARNING: NEVER ATTEMPT TO CATCH PISTON AS
IT LEAVES BORE. THIS COULD RESULT IN PER-
SONAL INJURY.

CAUTION: Do not blow piston out of bore with sus-
tained air pressure. This could result in a cracked
piston. Use only short spurts of air.

(5) Apply short spurts of low pressure air with

a rubber tipped blow gun through caliper brake hose
port. Use only enough air pressure to ease piston out.

(6) Remove C-clamp and block of wood from cali-

per and clamp it over dust boot of first piston
removed. This will seal empty piston bore.

(7) Move padded piece of wood in front of piston

yet to be removed.

(8) Remove second piston using same procedure

with short spurts of low pressure air.

(9) Remove C-clamp and block of wood from cali-

per.

(10) Remove piston dust boots with an appropriate

pry tool (Fig. 19).

CAUTION: Use an appropriate tool to remove piston
seals to avoid scratching piston bore. Do not use a
screwdriver or other metal tool to remove seals.

(11) Remove piston seals from caliper (Fig. 20).
(12) Remove caliper bleeder screw.

(13) Clean piston bore and drilled passage ways

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

(14) Inspect both piston and bore for scoring or pit-

ting. Bores that show light scratches or corrosion can
usually be cleared of light scratches or corrosion
using crocus cloth.

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.

Fig. 19 Piston Dust Boot Removal

1 - CALIPER
2 - DUST BOOT

Fig. 20 Piston Seal

1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL

CS

BRAKES - BASE

5 - 15

DISC BRAKE CALIPER - FRONT (Continued)

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 piston boot area

• Ruptures, brittleness or damage to the piston

dust boot

If caliper fails inspection, disassemble and recondi-

tion caliper, replacing the seals and dust boots.

ASSEMBLY

CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Ensure assembly area is clean and dry.

NOTE: Always use new, clean Mopar

T

DOT 3 Motor

Vehicle Brake Fluid when assembling brake caliper.

NOTE: Never use old piston seals or boots.

(1) Lubricate caliper pistons, piston seals and pis-

ton bores with clean, fresh brake fluid.

(2) Install NEW piston seals into caliper piston

bores (Fig. 21).

NOTE: Verify seal is fully seated and not twisted.

(3) Install NEW boot on each piston and work boot

lip into groove at top of piston. Stretch boot rearward

straightening boot folds, then move boot forward as
necessary until folds snap into place.

(4) Install first piston into caliper piston bore,

pressing piston down to bottom of bore using hand-
pressure (Fig. 22). Using a piece of wood or wooden
hammer handle may also suffice as long as piston
and boot damage is avoided.

(5) Seat dust boot in caliper counterbore using

Installer, Special Tool L-4410, with Handle, Special
Tool C-4171. Install dust boot until it bottoms (Fig.
23). Do not over-seat dust boot.

(6) Install second piston and dust boot using same

procedure as first.

(7) Install caliper bleeder screw.

Fig. 21 Piston Seal Installation

1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL

Fig. 22 Caliper Piston Installation

1 - CALIPER
2 - DUST BOOT
3 - PISTON

Fig. 23 Seating Dust Boot

1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER

5 - 16

BRAKES - BASE

CS

DISC BRAKE CALIPER - FRONT (Continued)

(8) Install

caliper

on

vehicle.

(Refer

to

5

-

BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER - INSTALLATION)

INSTALLATION

CAUTION: If adhesive is missing from noise sup-
pression gasket on rear of either inner and outer
brake shoes or if gasket is damaged, replace brake
shoes. (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/BRAKE PADS/SHOES - REMOVAL)

CAUTION: Use care when installing caliper onto
disc brake adapter to avoid damaging boots on cal-
iper guide pins.

(1) Install disc brake caliper over brake shoes on

brake caliper adapter.

CAUTION: To avoid possible noise or roughness
concerns, it is crucial that upper caliper guide pin
bolt (closest to bleeder screw) be tighten to speci-
fications first before tightening lower guide pin bolt.

(2) Align caliper guide pin bolt holes with guide

pins, then install caliper guide pin bolts (Fig. 6).
Tighten upper (closest to bleeder screw) bolt to 43
N·m (32 ft. lbs.) torque, then tighten lower bolt to 43
N·m (32 ft. lbs.) torque.

(3) Install banjo bolt attaching brake hose to cali-

per (Fig. 16). Install NEW washers on each side of
hose fitting as banjo bolt is placed through fitting.
Thread banjo bolt into caliper and tighten to 47 N·m
(35 ft. lbs.) torque.

(4) Install tire and wheel assembly (Refer to 22 -

TIRES/WHEELS - INSTALLATION). Tighten wheel
mounting nuts to 135 N·m (100 ft. lbs.) torque.

(5) Lower vehicle.
(6) Remove brake pedal holding tool.
(7) Connect battery negative cable to battery post.
(8) Bleed base brake hydraulic system as neces-

sary. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)

(9) Road test vehicle making several stops to wear

off any foreign material on brakes and to seat brake
shoes.

DISC BRAKE CALIPER - REAR

REMOVAL

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).

(1) Disconnect and isolate battery negative cable

from battery post.

(2) Using a brake pedal holding tool as shown (Fig.

15), depress brake pedal past its first inch of travel
and hold it in this position. Holding pedal in this
position will isolate master cylinder from hydraulic
brake system and will not allow brake fluid to drain
out of brake fluid reservoir while brake lines are
open.

(3) Raise and support vehicle. (Refer to LUBRICA-

TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)

(4) Remove wheel and tire assembly.
(5) Remove banjo bolt connecting brake hose to

caliper (Fig. 24). There are two sealing washers (one
one each side of hose fitting) that will come off when
bolt is removed. Discard these washers; install new
washers on installation.

(6) Remove disc brake caliper guide pin bolts (Fig.

24).

(7) Remove caliper assembly from brake adapter

by first rotating bottom of caliper away from rotor,
then lifting caliper (with shoes) away from upper
adapter abutment (Fig. 25).

(8) Remove outboard brake shoe by pushing shoe

away from caliper fingers, dislocating locating pins
built into shoe backing plate from holes in caliper
fingers, then sliding brake shoe down and off of
brake caliper (Fig. 26).

(9) Pull inboard brake shoe away from caliper pis-

ton, dislocating retaining clip from cavity in piston.
Remove inboard shoe.

Fig. 24 Rear Brake Caliper Mounting

1 - BRAKE HOSE BANJO FITTING
2 - CALIPER GUIDE PIN BOLT
3 - CALIPER ADAPTER
4 - DISC BRAKE CALIPER
5 - COPPER SEAL WASHERS
6 - BANJO BOLT

CS

BRAKES - BASE

5 - 17

DISC BRAKE CALIPER - FRONT (Continued)

DISASSEMBLY

DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS

NOTE: Before disassembling brake caliper, clean
and inspect it. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/DISC BRAKE CALIPER - CLEANING)
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPER - INSPECTION)

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

towards rear of caliper, and at same time, pull sleeve
out rear of caliper and bushing (Fig. 27).

(2) Using fingers, collapse one side of rubber guide

pin bushing. Pull guide pin bushing out other side of
brake caliper mounting boss (Fig. 28).

Fig. 25 Rear Caliper Removal

Fig. 26 Outboard Shoe Removal

1 - LOCATING PIN
2 - RETAINING CLIP
3 - HOLES

Fig. 27 Removing Sleeve From Bushing

1 - CALIPER
2 - SLEEVE
3 - BUSHING

Fig. 28 Removing Bushing From Caliper

1 - CALIPER
2 - BUSHING

5 - 18

BRAKES - BASE

CS

DISC BRAKE CALIPER - REAR (Continued)