Chrysler Pacifica. Manual — part 455
DRAULIC/MECHANICAL/ROTORS
-
STANDARD
PROCEDURE)
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted
on-car
brake
lathe
(Fig.
62),
or
replaced.
The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle’s hub and bearing.
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 63) or stamped into the hat section.
Minimum
thickness
specifications
can
also
be
found in the specification table in this section.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTOR - SPECIFICATIONS)
Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before lathe installation, verify the brake rotor
face and the hub adapters are free of any chips, rust,
or contamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer’s operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required. Specifi-
cations for brake rotor machining can be found in
this
sections
specification
table.
(Refer
to
5
-
BRAKES/HYDRAULIC/MECHANICAL/ROTOR
-
SPECIFICATIONS)
REMOVAL
REMOVAL - FRONT
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).
(1) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(2) Remove tire and wheel assembly.
Fig. 62 On-Car Brake Lathe
1 - ON-CAR BRAKE LATHE
Fig. 63 Minimum Brake Rotor Thickness (Typical)
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
CS
BRAKES - BASE
5 - 35
ROTOR (Continued)
NOTE: In some cases, it may be necessary to
retract caliper piston in its bore a small amount in
order to provide sufficient clearance between shoes
and rotor to easily remove caliper from knuckle.
This can usually be accomplished before mounting
bolts are removed, by grasping rear of caliper and
pulling outward working with guide pins, thus
retracting piston. Never push on piston directly as
it may get damaged.
(3) Remove two bolts securing disc brake caliper
adapter to steering knuckle (Fig. 64).
(4) Remove disc brake caliper and adapter from
knuckle as an assembly (Fig. 64). Hang assembly out
of way using wire or a bungee cord. Use care not to
overextend brake hose when doing this.
(5) Remove clips retaining brake rotor to wheel
studs (Fig. 65).
(6) Remove brake rotor (Fig. 65).
REMOVAL - REAR
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).
(1) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(2) Remove tire and wheel assembly.
NOTE: In some cases, it may be necessary to
retract caliper piston in its bore a small amount in
order to provide sufficient clearance between shoes
and rotor to easily remove caliper from knuckle.
This can usually be accomplished before guide pin
bolts are removed, by grasping rear of caliper and
pulling outward working with guide pins, thus
retracting piston. Never push on piston directly as
it may get damaged.
(3) Remove two caliper guide pin bolts (Fig. 66).
(4) 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. 67).
(5) To prevent weight of caliper from overextend-
ing and damaging brake hose while caliper is off
mount, hang brake caliper from vehicle using wire or
cord (Fig. 68).
(6) Remove any clips retaining brake rotor to
wheel mounting studs (Fig. 69).
(7) Remove brake rotor from hub (Fig. 69).
INSTALLATION
INSTALLATION - FRONT
NOTE: Inspect brake shoes before installation.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSPECTION)
Fig. 64 Front Caliper With Adapter Mounting To
Knuckle
1 - BRAKE ROTOR
2 - BRAKE CALIPER/ADAPTER ASSEMBLY
3 - MOUNTING BOLT
4 - KNUCKLE
Fig. 65 Front Brake Rotor Mounting
1 - HUB AND BEARING
2 - BRAKE ROTOR
3 - CLIP
5 - 36
BRAKES - BASE
CS
ROTOR (Continued)
(1) Clean hub face to remove any dirt or corrosion
where rotor mounts.
(2) Install brake rotor over studs on hub and bear-
ing (Fig. 65).
(3) Install disc brake caliper and adapter assembly
over brake rotor (Fig. 64).
(4) Install mounting bolts securing caliper adapter
to steering knuckle (Fig. 64). Tighten bolts to 169
N·m (125 ft. lbs.) torque.
(5) Install tire and wheel assembly (Refer to 22 -
TIRES/WHEELS - INSTALLATION). Tighten wheel
mounting nuts to a torque of 135 N·m (100 ft. lbs.).
(6) Lower vehicle.
(7) Pump brake pedal several times to ensure vehi-
cle has a firm brake pedal before moving vehicle.
(8) Check and adjust brake fluid level as neces-
sary.
Fig. 66 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
Fig. 67 Rear Caliper Removal
Fig. 68 Supporting Caliper
1 - BRAKE HOSE
2 - SUSPENSION
3 - WIRE HANGER (HANG TO VEHICLE/SUSPENSION)
4 - BRAKE CALIPER
Fig. 69 Rear Brake Rotor Mounting
1 - HUB
2 - RETAINER CLIP
3 - BRAKE ROTOR
CS
BRAKES - BASE
5 - 37
ROTOR (Continued)
(9) Road test vehicle and make several stops to
wear off any foreign material on brakes and to seat
brake shoes.
INSTALLATION - REAR
NOTE: Inspect disc brake shoes and parking brake
shoes before installation. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE
PADS/SHOES
-
INSPECTION)
(1) Clean hub face to remove any dirt or corrosion
where rotor mounts.
(2) Install brake rotor over wheel mounting studs
and onto hub (Fig. 69).
(3) Make sure abutment shims are in place on
both slide abutments of caliper adapter.
CAUTION: Use care when installing caliper assem-
bly onto adapter so guide pin bushings and sleeves
do not get damaged by mounting bosses on
adapter.
(4) Retract caliper guide pins to clear mounting
bosses on caliper adapter when installing caliper.
(5) Install brake caliper in opposite way it was
removed. Starting with upper end, carefully position
caliper and brake shoes over brake rotor and align
outboard shoe’s upper edge with caliper slide abut-
ment. Rotate lower end of caliper into mounting posi-
tion on adapter.
CAUTION: Extreme caution should be taken not to
crossthread caliper guide pin bolts when they are
installed.
(6) Carefully install caliper guide pin bolts (Fig.
66). Tighten bolts to 23 N·m (200 in. lbs.) torque.
(7) Install tire and wheel assembly (Refer to 22 -
TIRES/WHEELS - INSTALLATION). Tighten wheel
mounting nuts to a torque of 135 N·m (100 ft. lbs.).
(8) Lower vehicle.
(9) Pump brake pedal several times to ensure vehi-
cle has a firm brake pedal before moving vehicle.
(10) Check and adjust brake fluid level as neces-
sary.
(11) Road test vehicle and make several stops to
wear off any foreign material on brakes and to seat
brake shoes.
SPECIFICATIONS
BRAKE ROTOR
NOTE: When refacing a rotor, the required TIR
(Total Indicator Reading) and thickness variation
limits MUST BE MAINTAINED. Extreme care in the
operation of rotor turning (machining) equipment is
required.
LIMITS/SPECIFICATIONS
Brake Rotor
Rotor Thickness
Minimum Rotor
Thickness
Rotor
Thickness
Variation
Rotor Runout *
Front
27.87-28.13 mm
1.097-1.107 in.
26.5 mm
1.040 in
0.009 mm
0.0004 in.
0.035 mm
0.0014 in.
Rear
13.87-14.13 mm
0.546-0.556 in.
12.5 mm
0.492 in.
0.009 mm
0.0004 in.
0.14 mm
0.0055 in.
* TIR Total Indicator Reading (Measured On Vehicle)
PARKING BRAKE
STANDARD PROCEDURE
STANDARD PROCEDURE - AUTOMATIC
ADJUSTER LOCKING OUT
(1) Place an assistant inside passenger compart-
ment with pin (pin punch or drill bit) to be used in
Step 5.
(2) Place parking brake lever in “released” posi-
tion.
(3) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(4) Grasp exposed section of parking brake cable
at cable connector (front-to-right rear cable) (Fig.
70)and pull outward on front cable. Pull on cable
until it stops and hold it in this position.
(5) Have assistant inside passenger compartment
insert pin punch (locking pin or drill bit) into hole in
lever and foot pedal, past tang on adjuster mecha-
nism, and through hole in backing plate of lever (Fig.
71) (Fig. 72). Hold pin in place. This pin will lock
5 - 38
BRAKES - BASE
CS
ROTOR (Continued)
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