Chrysler New Yorker. Manual — part 39
Fig. 3 Piston Seal Function for Automatic
Adjustment Of Front Brakes
Fig. 1 Front Disc Brake Caliper Assembly
Fig. 2 Disc Brake Caliper Mounting
5 - 2
BRAKES
300M
DESCRIPTION AND OPERATION (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. 4).
(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. 5).
(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. 6).
(7) If required, remove rotor from hub by pulling it
straight off wheel mounting studs (Fig. 7).
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.
Fig. 4 Removing Caliper Assembly Guide Pin Bolts
Fig. 5 Removing Caliper Assembly
Fig. 6 Storing Caliper
300M
BRAKES
5 - 3
(2) If removed, install rotor on hub (Fig. 7).
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. 5).
(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 guide pin bolts 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.
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 outboard brake shoe, by prying the
shoe retaining clip over raised area on caliper. Then
slide the brake shoe off the caliper (Fig. 8).
(3) Pull inboard brake shoe away from piston,
until retaining clip is free from cavity in piston (Fig.
9).
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.
Fig. 7 Removing Or Installing Braking Disc
5 - 4
BRAKES
300M
REMOVAL AND INSTALLATION (Continued)
(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. 10) for inboard and out-
board brake shoe assembly identification.
NOTE: When installing inboard brake shoe into cal-
iper piston, be sure brake shoe is positioned
squarely against the face of the caliper piston.
(4) Install the new inboard brake shoe assembly
into the caliper piston by firmly pressing it into bore
of caliper piston with thumbs (Fig. 9).
(5) Slide the new outboard brake shoe assembly
onto the caliper assembly (Fig. 11).
(6) Reinstall caliper as described in Front Disc
Brake Caliper Removal and Installation, found else-
where in this section of this service manual.
CAUTION: Before vehicle is moved after performing
a service procedure on the vehicle brake system,
pump the brake pedal several times to insure the
vehicle has a firm brake pedal that is to adequate to
stop the vehicle.
(7) 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. 8 Removing Outboard Brake Shoe
Fig. 9 Inboard Brake Shoe
Fig. 10 Front Brake Shoe Assembly Identification
Fig. 11 Installing Outboard Brake Shoe Assembly
300M
BRAKES
5 - 5
REMOVAL AND INSTALLATION (Continued)
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