Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 155
5. Remove banjo bolt (4) connecting flexible brake
hose (3) to caliper (1). There are two sealing wash-
ers (2) (one one each side of hose fitting) that will
come off when bolt is removed. Discard these
washers; install NEW washers on installation.
6. While holding guide pins from turning, remove cal-
iper guide pin bolts (2).
7. Remove brake caliper (1) from brake adapter (3)
and pads.
DISASSEMBLY
NOTE: Before disassembling brake caliper, clean and inspect it. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPER - CLEANING) (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER - INSPECTION)
WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper
bore. Personal injury could result from such a practice.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause
bore distortion.
1. Drain brake fluid from caliper.
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BRAKES - BASE
LX
2. Mount caliper in a vise equipped with protective
jaws.
3. Place a wooden block (2) (padded with approxi-
mately one-inch thickness of shop towels) in front
of caliper (1) piston as shown. Padded block
should be sized to allow piston to push out of bore
far enough to be removed by hand after being
loosened by air pressure, yet large enough to keep
piston from coming completely out. This will cush-
ion and protect caliper piston during removal.
WARNING: Do not place face or hands near caliper
and piston if using compressed air pressure to
remove piston. Do not use high pressure.
4. Apply low pressure compressed air to caliper fluid
inlet in short spurts to ease piston out of bore.
5. Remove piston from caliper (1).
CAUTION: When working on disc brake caliper,
always use care and suitable tools to avoid dam-
aging the aluminum housing.
6. Using a suitable tool (1), carefully remove dust
boot (2) and discard it.
CAUTION: Do not use a screw driver or other
metal tool for seal removal. Using such tools can
scratch bore or leave burrs on seal groove edges.
7. Using a soft tool such as a plastic trim stick (2),
work piston seal (1) out of its groove in caliper pis-
ton bore. Discard used seal.
LX
BRAKES - BASE
5 - 63
8. Remove caliper bleeder screw (1) from caliper
housing (2).
9. Clean piston bore and drilled passage ways with
alcohol or a suitable solvent. Wipe it dry using only
a lint-free cloth.
10. Inspect both piston and bore for scoring or pitting.
NOTE: It is not recommended to hone caliper
bore.
The
anodized
coating
would
be
compromised.
CLEANING
WARNING: Dust and dirt accumulating on brake parts during normal use may contain 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 contain 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 containing
asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the
Occupational 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-Chlorinated Brake
Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to
clean the caliper. These fluids will damage rubber cups and seals.
INSPECTION
Inspect the disc brake caliper for the following:
•
Cracked or damaged housing
•
Brake fluid leaks in and around boot area
•
Ruptures, brittleness or damage to the piston dust boot
If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots or replace caliper.
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage caliper seals. Ensure assembly area is clean and dry.
NOTE: Always use new, clean Mopar
T
DOT 3 Motor Vehicle Brake Fluid or equivalent when assembling
brake caliper.
NOTE: Never use used or old piston seals or boots for reassembly.
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BRAKES - BASE
LX
1. Lubricate caliper piston, piston seal (1) and piston
bore (2) with clean, fresh brake fluid.
2. Install NEW piston seal (1) in groove of caliper
bore (2). Seal should be started at one area of
groove and gently worked around and into the
groove using only your clean fingers to seat it.
3. Install NEW dust boot (1) on piston (2) and work
boot lip into groove at top of piston. Stretch boot
downward, straightening boot folds, then move
boot back upward as necessary until folds snap
uniformly into place.
4. Install piston (1) into caliper piston (2) bore, press-
ing piston down to bottom of bore using hand-pres-
sure. Using a piece of wood or wooden hammer
handle may also suffice as long as piston and boot
damage can be avoided.
LX
BRAKES - BASE
5 - 65
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