Dodge Caliber. Manual — part 99
NOTE: The lubricant used on the guide pin portion
of the guide pin bolt is Niglube RM. Use the appro-
priate lubricant when necessary.
3. Rotate the disc brake caliper downward over the
brake rotor and lower part of caliper adapter.
4. Install the disc brake caliper (2) lower guide pin
bolt (1). Tighten the guide pin bolt to 43 N·m (32 ft.
lbs.).
5. Install tire and wheel assembly (1) (Refer to 22 -
TIRES/WHEELS - INSTALLATION). Install and
tighten the wheel mounting nuts (3) to 135 N·m
(100 ft. lbs.).
6. Lower the vehicle.
7. Pump the brake pedal several times before moving
the vehicle to set the pads to the brake rotor.
8. Check and adjust the brake fluid level in the reser-
voir as necessary.
9. Road test the vehicle and make several stops to
seat the brake pads to the rotor.
PM
BRAKES - BASE
5 - 97
SPECIFICATIONS
BRAKE ROTOR LIMITS/SPECIFICATIONS
NOTE: When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST
BE MAINTAINED.
Braking Rotor
Rotor Thickness
Minimum Rotor
Thickness
Rotor Thickness
Variation
Rotor Runout*
Front Rotor
(15-inch**)
25.90–26.10 mm
1.020–1.028 in.
24.40 mm
0.961 in.
0.005 mm
0.0002 in.
0.05 mm
0.002 in.
Front Rotor
(16-inch***)
25.90–26.10 mm
1.020–1.028 in.
24.40 mm
0.961 in.
0.005 mm
0.0002 in.
0.05 mm
0.002 in.
Rear Rotor
9.80–10.20 mm
0.386–0.402 in.
8.40 mm
0.331 in.
0.015 mm
0.0006 in.
0.06 mm
0.0024 in.
* TIR Total Indicator Reading (Measured On Vehicle)
** Referred to as “15-inch” because they are designed to fit inside 15-inch or larger wheels. Actual rotor diameter
is 10.8 in. (276 mm).
*** Referred to as “16-inch” because they are designed to fit inside 16-inch or larger wheels. Actual rotor diameter
is 11.5 in. (294 mm).
5 - 98
BRAKES - BASE
PM
TUBES/HOSES
DESCRIPTION
The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces.
The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end. The fitting at each
front brake caliper is the banjo-type and requires a special banjo bolt and copper washers. The fitting at each rear
brake caliper is a screw-in type fitting. Rear drum brake vehicles use a standard tube nut fitting at each wheel
cylinder.
INSPECTION
Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot com-
ponents.
Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should
be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first.
Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes
exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deteri-
oration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.
PM
BRAKES - BASE
5 - 99
PLATE-SUPPORT, BRAKE BACKING
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING) (Refer to 5 - BRAKES - CAUTION).
1. Using a brake pedal holding tool as shown,
depress the brake pedal past its first one inch of
travel and hold it in this position. This will isolate
the master cylinder from the brake hydraulic sys-
tem and will not allow the brake fluid to drain out of
the master cylinder reservoir.
2. Raise and support the vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
3. Remove the wheel mounting nuts (3), then the tire
and wheel assembly.
5 - 100
BRAKES - BASE
PM
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