Chrysler New Yorker. Manual — part 27
Only double wall 4.75mm (3/16 in.) steel tubing
should be used for replacement of the chassis brake
tubes. The chassis brake tubes used on this
vehicle are coated with a zinc alloy and alumi-
num rich coating referred to as Prokote 2000. If
a chassis brake tube requires replacement, only
brake tubing with the same coating should be
used as a service replacement. Care should be
taken when replacing brake tubing, to be sure the
proper bending and flaring tools and procedures are
used, to avoid kinking. Do not route the tubes
against sharp edges, moving components or into hot
areas. All tubes should be properly attached with rec-
ommended retaining clips and fasteners.
Care must be taken when servicing components to
avoid damage to the flexible stainless steel hoses
between the master cylinder and junction block or
antilock hydraulic control unit.
ISO STYLE TUBE FLARING PROCEDURE
CAUTION:
ALWAYS USE THE PROPER TYPE OF
ISO FLARING TOOL AND REQUIRED PROCEDURE,
WHEN TUBE FLARING IS REQUIRED WHEN SER-
VICING THE VEHICLES HYDRAULIC BRAKE SYS-
TEM.
THIS
IS
REQUIRED
TO
ENSURE
THE
INTEGRITY OF THE VEHICLE’S HYDRAULIC BRAK-
ING SYSTEM.
Using Tubing Cutter, Special Tool C-3478-A or
equivalent, cut off damaged seat on tubing (Fig. 27).
Ream out any burrs or rough edges showing on
inside of tubing. This will make the ends of tubing
square (Fig. 28) and ensure better seating of flared
end tubing. Be sure to put the tube nut on tub-
ing before the tubing is flared.
CAUTION:
All ISO style tubing flares are of metric
dimensions. When performing any service proce-
dures on a vehicle using ISO style tubing flares,
metric size tubing of 4.75 mm MUST be used with
metric ISO tube flaring equipment.
To create a (metric) ISO style tubing flare, Use
Snap-On Flaring Tool TFM-428, (Fig. 27) or equiva-
lent. See (Fig. 29) and proceed with the steps listed
below. Be sure to place the tubing nut on tube
before proceeding to flare the tubing.
(1) Carefully prepare the end of the tubing to be
flared. Be sure the end of the tubing is square and
all burrs on the inside of the tubing are removed
(Fig. 28). This preparation is essential to obtain
the correct form of a (metric) ISO tubing flare.
(2) Open the jaws of the Flaring Tool. Align the
jaws of the flaring tool around the tubing. Close the
jaws of the Flaring Tool around the tubing, but do
not lock the tubing in place.
(3) Position tubing in jaws of the Flaring Tool so
that it is flush with top surface of flaring tool bar
assembly (Fig. 29).
(4) Install the correct size adaptor for the brake
tubing being flared, on the feed screw of the yoke
assembly. Center the yoke and adapter over the end
of the tubing. Apply lubricant to the adapter area
that contacts the brake tubing. Make sure the
adapter pilot is fully inserted in the end of the brake
tubing. Tighten screw on yoke assembly until the
adaptor has seated squarely on the surface of the bar
assembly (Fig. 29). This process will properly create
a metric ISO tubing flare.
Fig. 27 Cutting and Flaring of Brake Line Tubing
Fig. 28 Tube End Properly Prepared For Flaring
5 - 22
BRAKES
300M
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
FRONT DISC BRAKE CALIPER
During service procedures, grease or any other for-
eign material must be kept off brake shoe assem-
blies, and braking surfaces of rotor.
Handle the rotor and caliper carefully, to avoid
damaging the rotor and/or scratching or nicking of
brake shoe lining.
If inspection reveals that the caliper piston seal is
leaking, it MUST be replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove front wheel and tire assemblies from
vehicle.
(3) Remove the 2 caliper assembly to steering
knuckle guide pin bolts (Fig. 30).
(4) Remove
caliper
assembly
from
steering
knuckle. Proceed by first rotating top of caliper away
from steering knuckle and then lifting caliper off bot-
tom machined abutment on steering knuckle (Fig.
31).
(5) If the caliper is to be completely removed from
the vehicle, remove the banjo bolt connecting the
brake flex hose to the caliper. There will be 2 wash-
ers (one on each side of the flex hose fitting) that will
come off at the same time.
(6) If the caliper is not being completely removed
from the vehicle, support the caliper firmly to pre-
vent weight of caliper from damaging the flexible
brake hose (Fig. 32).
(7) If required, remove rotor from hub by pulling it
straight off wheel mounting studs (Fig. 33).
Fig. 29 ISO Tubing Flare Tool
Fig. 30 Removing Caliper Assembly Guide Pin Bolts
Fig. 31 Removing Caliper Assembly
300M
BRAKES
5 - 23
SERVICE PROCEDURES (Continued)
INSTALL
CAUTION:
Use care when installing the caliper
assembly on the steering knuckle, so seals on cal-
iper guide pin bushings do not get damaged by the
steering knuckle bosses.
(1) Completely retract the caliper piston back into
the piston bore of the caliper, if new brake shoes
have been installed.
(2) If removed, install rotor on hub (Fig. 33).
NOTE: Make sure shoe retainer clips are in position
between the shoe backing plates on each end of
shoes before caliper installation.
(3) Carefully
position
caliper
and
brake
shoe
assemblies over rotor using the reversed required
removal procedure (Fig. 31).
(4) Install the banjo bolt connecting the flex hose
to the caliper. One washer should be installed on
each side of the flex hose fitting before installing the
banjo bolt. Tighten banjo bolt to a torque of 48 N·m
(35 ft. lbs.).
CAUTION: When being installed, extreme caution
should be taken not to crossthread the caliper
guide pin bolts.
(5) Install the caliper guide pin bolts. Tighten
guide pin bolts to a torque of 22 N·m (192 in. 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 129 N·m (95 ft. lbs.).
(8) Remove jackstands or lower hoist. Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal to adequately stop vehicle.
WARNING: Before moving vehicle after performing
any service to the vehicle brake system, be sure to
obtain a firm brake pedal.
(9) 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. 32 Storing Caliper
Fig. 33 Removing Or Installing Braking Disc
5 - 24
BRAKES
300M
REMOVAL AND INSTALLATION (Continued)
FRONT DISC BRAKE SHOES
WARNING:
ALTHOUGH
FACTORY
INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE’S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN
CLEANING
BRAKE
COMPONENTS
AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKE LINING DUST BY SANDING BRAKE
LININGS WHEN SERVICING A VEHICLE. DISPOSE
OF ALL DUST AND DIRT SUSPECTED OF CONTAIN-
ING ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT
BAGS
OR
CONTAINERS.
FOLLOW ALL
RECOMMENDED
SAFETY
PRACTICES
PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION (OSHA) AND THE ENVI-
RONMENTAL PROTECTION AGENCY (EPA), FOR
HANDLING AND DISPOSAL OF PRODUCTS CON-
TAINING ASBESTOS.
REMOVE
(1) Remove caliper as described in Front Disc
Brake Caliper Removal and Installation, found else-
where in this section of this service manual.
(2) Remove the shoe retractor clips from between
the shoes.
(3) Remove outboard brake shoe, by prying the
shoe retaining clip over raised area on caliper. Then
slide the brake shoe off the caliper (Fig. 34).
(4) Pull inboard brake shoe away from piston,
until retaining clip is free from cavity in piston (Fig.
35).
CALIPER INSPECTION
Check for piston seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
or fluid leak is visible, disassemble caliper assembly
and install a new seal and boot, (and piston if
scored). Refer to procedures titled Disc Brake Caliper
Disassembly.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brit-
tle. Refer to Cleaning And Inspection Of Brake Caliper.
INSTALL
NOTE:
Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both steering knuckle abutments
with a liberal amount of Mopar
t Brake Grease for
Caliper Slides Lubricant, or equivalent.
(3) Remove the protective paper from the noise
suppression gasket on both the inner and outer brake
shoe assemblies (if equipped).
NOTE: The inboard and outboard brake shoes are
not common, refer to (Fig. 36) for inboard and out-
board brake shoe assembly identification.
Fig. 34 Removing Outboard Brake Shoe
Fig. 35 Inboard Brake Shoe
300M
BRAKES
5 - 25
REMOVAL AND INSTALLATION (Continued)
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