1993 CHEVROLET PLYMOUTH ACCLAIM wheel bolts

material, (Fig. 7). Be sure inboard brake shoe assem-
bly is correctly positioned against anti-rattle clip
(Fig. 6). (4) Reinstall the Braking Disk on the hub, by in-
stalling it over the wheel studs until it is seated
against the face of the hub (Fig. 6). (5) Slide the new outboard brake shoe assembly on
the adapter abutment, (Fig. 5). (6) Carefully lower caliper over the braking disk and
brake shoe assemblies (Fig. 3). Make sure that the
caliper guide pin bolt, bushings and sleeves are clear of
the adapter. (7) Install the caliper guide pin bolts and tighten to
34 to 37 N Im (25 to 35 ft. lbs.). Extreme caution
should be taken not to cross the threads of the
caliper guide pin bolts. (8) Install the wheel and tire assembly. Tighten the
wheel mounting stud nuts in proper sequence (Fig. 9)
until all nuts are torqued to half specification. This is
important. Then repeat the tightening sequence to the
full specified torque of 129 N Im (95 ft. lbs.).
(9) Remove jackstands or lower hoist. Before mov-
ing vehicle, pump the brake pedal several times
to insure the vehicle has a firm brake pedal to
adequately stop vehicle. .
(10) Road test the vehicle and make several stops to
wear off any foreign material on the brake linings and
to seat the brake shoe linings.
Fig. 8 Remove Or Replace Anti-Rattle Clip
Fig. 9 Tightening Wheel Nuts
Ä BRAKES 5 - 37

KELSEY HAYES DOUBLE PIN NON-FAMILY CALIPER INDEX
page page
Assembling Disc Brake Caliper .............. 42
Cleaning and Inspection of Brake Caliper ...... 41 Disc Brake Caliper Disassembly
............. 40
Service Procedures ....................... 38
SERVICE PROCEDURES
BRAKE SHOES REMOVE
(1) Raise the vehicle on jackstands or centered on
a hoist. (2) Remove the front wheel and tire assemblies
from the vehicle. (3) Remove the brake caliper assembly to steering
knuckle attaching guide pin bolts (Fig. 1) (4) Pull lower end of brake caliper out from the
machined abutment on the steering knuckle (Fig. 2).
Then roll caliper out and away from braking disc
(Fig. 2). The brake shoe assemblies will remain with
the brake caliper. (5) When the caliper is removed from the vehicle
to service the brake shoes. SUPPORT CALIPER
FIRMLY TO PREVENT WEIGHT OF CALIPER
FROM DAMAGING THE FLEXIBLE HOSE. (See
Fig. 3). (6) Remove the outboard brake shoe by prying be-
tween the top of the outboard shoe and the top of the
caliper assembly as shown in (Fig. 4). (7) Remove the inboard brake shoe from the cali-
per, by pulling the inboard shoe assembly away from
the piston (Fig. 5).
Fig. 1 Non-Family Disc Brake Assembly
Fig. 2 Removing Caliper and Brake Shoes as an Assembly
5 - 38 BRAKES Ä

iper, by installing retaining clip into the bore of the
piston (Fig. 5).
CAUTION: Use care when installing the caliper as-
sembly onto the steering knuckle, so the seal on the
sealed for life bushings does not get damaged.
(5) Carefully lower caliper over braking disc and
guide holddown spring under machined abutment on
knuckle assembly (Fig. 8).
(6) Install caliper guide pin bolts and tighten to
24-34 N Im (18-25 ft. lbs.) torque. When installing guide pin bolts, use extreme caution not to cross
thread the guide pin bolts.
(7) Install wheel and tire assembly. Tighten stud
nuts in proper sequence until all nuts are torqued to
half specification. This is important. Then repeat
sequence to full specification. (8) Remove jackstands or lower hoist. Before mov-
ing vehicle be sure it has a firm pedal, pump
pedal several times. (9) Road test vehicle and make several stops to
wear off any foreign material on the brakes and
to seat the linings.
DISC BRAKE CALIPER DISASSEMBLY
CLEANING AND INSPECTION
Check for piston fluid seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of piston dust boot. If boot is damaged, or fluid
leak is visible, disassemble caliper assembly and in-
stall 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 bushings
to determine if they are in good condition. Replace if
they are damaged, dry, or found to be brittle. Refer to
Cleaning And Inspection Of Brake Caliper. (1) Remove caliper from braking disc (See Brake
Shoe Removal). Hang assembly on a wire hook away
from braking disc, so hydraulic fluid cannot get on
braking disc (See Fig. 3 in Brake Shoe Removal). Place
a small piece of wood between the piston and caliper
fingers. (2) Carefully depress brake pedal to hydraulically
push piston out of bore. (Brake pedal will fall away
when piston has passed bore opening.) Then prop up
the brake pedal to any position below the first inch of
pedal travel, this will prevent loss of brake fluid from
the master cylinder. (3) If both front caliper pistons are to be removed,
disconnect flexible brake line at frame bracket after
removing piston. Plug brake tube and remove piston
from opposite caliper. Using the same process as above
for the first piston removal.
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE BE USED TO REMOVE PISTON FROM
CALIPER BORE. PERSONAL INJURY COULD RE-
SULT FROM SUCH A PRACTICE.
(4) Disconnect brake flexible hose from the caliper.
To disassemble, mount caliper assembly in a vise
equipped with protective jaws.
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
Fig. 7 Installing Outboard Shoe Assembly onto Cali- per
Fig. 8 Guiding Holddown Spring Under MachinedAbutment
5 - 40 BRAKES Ä

REAR DISC BRAKES INDEX
page page
Assembling Rear Disc Brake Caliper .......... 49
Brake Shoe Removal ..................... 46
Cleaning and Inspection ................... 49
Disassembling Rear Caliper Assembly ......... 48 General Information
....................... 45
Lining Wear ............................. 45
Service Precautions ....................... 46
GENERAL INFORMATION
The rear disc brakes are similar to front disc
brakes, however, there are several distinctive fea-
tures that require different service procedures. This
single piston, floating caliper rear disc brake assem-
bly includes a hub assembly, adapter, braking disc
(rotor), caliper, shoes and linings. The parking brake
system on all vehicles equipped with rear disc
brakes. Consists of a small duo-servo drum brake
mounted to the caliper adapter. The drum brake
shoes expand out against a braking surface (hat sec-
tion) on the inside area of the braking disk (rotor). The AC and AY body vehicles are equipped with a
caliper assembly that has a 36 mm (1.42 inch) piston,
and utilizes a 14 inch solid braking disc (rotor). The AA body vehicle are equipped with a caliper
assembly that uses a 34 mm (1.34 inch) piston. The
AA body uses the same 14 inch solid braking disc
(rotor) as on the AC and AY applications. Also avail-
able on the AA body is a caliper assembly with a 36
mm (1.42 inch) piston, with a 15 inch vented braking
disc (rotor). The AG AJ and AP body vehicles are also equipped
with different size caliper pistons depending on the size and type of braking disk used on the vehicle.
The 14 9solid braking disk (rotor) applications use a
34 mm (1.34 inch) piston, and the 15 9vented braking
disk (rotor) applications use a 36 mm (1.42 inch) pis-
ton. The caliper assembly on all applications float on
rubber bushings using internal metal sleeves which
are attached to the adapter using threaded guide pin
bolts. The adapter is mounted to the rear axle of the ve-
hicle and is used to mount the brake shoes and actu-
ating cables for the parking brake system. The
adapter also mounts the rear caliper assembly to the
vehicle. The adapter has two machined abutments
which are used to position and align the caliper and
brake shoes for movement for and aft (Fig. 1)
LINING WEAR
To check the amount of lining wear, remove the
wheel and tire assemblies. If a visual inspection does
not adequately determine the condition of the lining,
Fig. 1 Rear Disc Brake Assembly
Ä BRAKES 5 - 45

removal will be necessary. Remove the shoe and lin-
ing assemblies (see Brake Shoe Removal).Combined shoe and lining thickness should be
measured at the thinnest part of the assembly. When a shoe and lining assembly is worn to a
thickness of approximately 7.0 mm (9/32 inch) it
should be replaced. Replace both shoe assemblies (inboard and out-
board) on both wheels whenever shoe assemblies on
either side are replaced. If a shoe assembly does not require replacement.
Reinstall it, making sure each shoe assembly is re-
turned to its original position on the wheel of the ve-
hicle from which it was removed. (See Brake Shoe
Installation).
SERVICE PRECAUTIONS
WARNING: DUST AND DIRT ON BRAKE PARTS
GENERATED DURING THE NORMAL USE AND
WEAR OF MOTOR VEHICLE BRAKE SYSTEMS CAN
CONTAIN ASBESTOS FIBERS. BREATHING EXCES-
SIVE CONCENTRATIONS OF ASBESTOS FIBERS
CAN CAUSE SERIOUS BODILY HARM, SUCH AS
ASBESTOSIS AND CANCER. EXTREME CARE
SHOULD BE EXERCISED WHILE SERVICING
BRAKE ASSEMBLIES OR COMPONENTS. DO NOT CLEAN BRAKE ASSEMBLIES OR COM-
PONENTS WITH COMPRESSED AIR OR BY DRY
BRUSHING; USE A VACUUM CLEANER SPECIFI-
CALLY RECOMMENDED FOR USE WITH ASBES-
TOS FIBERS. IF A SUITABLE VACUUM CLEANER IS
NOT AVAILABLE, CLEANING SHOULD BE DONE
WET USING A WATER DAMPENED CLOTH. DO NOT CREATE DUST BY SANDING, GRINDIN-
G,AND/OR SHAVING BRAKE LININGS OR PADS
UNLESS SUCH OPERATION IS DONE WHILE USING
PROPERLY EXHAUST VENTILATED EQUIPMENT. DISPOSE OF ALL DUST AND DIRT SUSPECTED
TO CONTAIN ANY ASBESTOS FIBERS IN SEALED
BAGS OR CONTAINERS TO MINIMIZE DUST EXPO-
SURE TO YOURSELF AND OTHERS. FOLLOW ALL RECOMMENDED PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION AND THE ENVIRON-
MENTAL PROTECTION AGENCY. FOR THE HAN-
DLING, PROCESSING, AND DISPOSITION OF DUST
OR DIRT WHICH MAY CONTAIN ASBESTOS FI-
BERS. IT IS RECOMMENDED NOT TO BREATH ANY
TYPE OF BRAKE LINING MATERIAL DUST EVEN
ASBESTOS FREE, DUE TO THE FIBROUS NATURE
OF THE MATERIALS BEING USED.
Grease or any other foreign material must be kept
off the caliper assembly, surfaces of the braking disc
and external surfaces of the hub, during service pro-
cedures. Handling the braking disc and caliper should be done
in such a way as to avoid deformation of the disc and
scratching or nicking the brake linings (pads). During removal and installation of a wheel and tire
assembly, use care not to strike the caliper. Before vehicle is moved after any brake service
work, be sure to obtain a firm brake pedal.
BRAKE SHOE REMOVAL
(1) Raise vehicle on jackstands or centered on a
hoist. (2) Remove rear wheel and tire assemblies.
(3) Remove caliper attaching bolts (Fig. 2).
(4) Lift caliper away from adapter rails (Fig. 3).
(5) Remove outboard shoe. By prying the shoe re-
taining clip over the raised area on the caliper. Then
slide the shoe down and off the caliper (Fig. 4). (6) Pull inboard shoe away from piston, until the
retaining clip is free from the cavity in the piston. (Fig.
5).
CLEANING AND INSPECTION
Check for piston seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of piston dust boot. If the boot is damaged, or
fluid leak is visible, disassemble caliper assembly and
install a new seal and boot (and piston if scored). Refer
to procedure titled Disc Brake Caliper Disassembly.
BRAKE SHOE INSTALLATION
(1) Retract piston.
If the originally removed brake shoe assem-
blies are to be replaced back on vehicle. Be sure
Fig. 2 Removing Caliper Attaching Bolts
5 - 46 BRAKES Ä

each brake shoe assembly is returned to its origi-
nal position on the wheel of the vehicle from
which it was removed. (2) Install inboard brake shoe by inserting shoe
retaining clip into piston cavity. Be sure brake shoe is
seated squarely on the face of the piston. (Fig. 5). (3) Install outboard shoe by sliding retaining clip
over caliper fingers. Be sure the brake shoe is installed
on the caliper, so the retaining clip is past the raised
area on the caliper fingers (Fig. 6). (4) Install lower end of caliper on to adapter. Make sure the lower tabs on the brake shoes and the cast-
ing projections on the caliper are under the adapter
rail (Fig. 7). (5) Rotate caliper down over rotor.
(6) Install caliper attaching bolts and tighten to 22
N Im (193 in. lbs.) torque (Fig. 8).
(7) Install wheel and tire assembly. Tighten stud
nuts in proper sequence until all nuts are torqued to
half specification. This is important. Then repeat
sequence to full specification. (8) Remove jackstands or lower hoist. Before mov-
ing vehicle be sure it has a firm pedal.
Fig. 5 Remove and Install Inboard Brake Shoe
Fig. 6 Installing Outboard Shoe
Fig. 3 Removing Caliper
Fig. 4 Removing Outboard Shoe
Ä BRAKES 5 - 47

BRAKES
CONTENTS
page page
BENDIX ANTILOCK 4 BRAKE SYSTEM ...... 12
GENERAL INFORMATION .................. 1 HYDRAULIC SYSTEM CONTROL VALVES . . . 10
SERVICE ADJUSTMENTS
.................. 3
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the break down of these designa-
tions is included in the Introduction Section at the
front of this service manual. Standard brake equipment consists of:
² Double pin floating caliper disc front brakes.
² Rear automatic adjusting drum brakes.
² Differential valve with a brake warning switch.
² Master cylinder.
² Vacuum power booster.
² Double pin floating caliper rear disc brakes are
available on some models. The Bendix Antilock 4 Brake System, uses the fol-
lowing standard brake system components. Master
cylinder, power booster, caliper assemblies, braking
discs, pedal assembly, brake lines and hoses. The
unique parts of the Bendix Antilock 4 Brake System
consists of the following components, modulator as-
sembly, unique proportioning valves, unique junction
block, wheel speed sensors, tone wheels, and elec-
tronic control unit. These components will be de-
scribed in detail in the Bendix Antilock 4 Brake
System section in this service manual supplement. The hydraulic system, (Fig. 1) on the Bendix Anti-
lock 4 brake system is diagonally split. Diagonally
split hydraulic brake systems, have the left front and
right rear brakes on one hydraulic system and the
right front and left rear on the other. A diagonally
split hydraulic brake system, will maintain half of
the vehicles braking capability if there is a failure in
either half of the hydraulic system. The Bendix Antilock 4 Brake System uses two
types of brake line fittings and tubing flares on the
modulator assembly (Fig. 1). The different types are
the ISO style and double wall style with their corre-
sponding fittings at different joint locations. See (Fig.
2) for specific joint locations and type of tubing
flares. CAUTION: When servicing a vehicle, sheet metal
screws, bolts or other metal fastener cannot be in-
stalled in a shock tower to take the place of any
original plastic clip. Also, NO holes can be drilled
into the front shock tower in the area shown in (Fig.
3), for installation of any metal fasteners into the
shock tower.
Because of minimum clearance in this area, (Fig.
3) installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of
the spring. If a plastic clip is missing, lost or broken
during servicing a vehicle, replace only with the
equivalent part listed in the Mopar parts catalog.
Fig. 1 Identifying Hydraulic Brake Tubing Flares
Ä BRAKES 5 - 1

(4) If equipped, remove the 2 bolts (Fig. 4) attaching
speed control vacuum reservoir to battery tray. Then
remove vacuum reservoir (Fig. 4) from the battery tray.
Vacuum lines (Fig. 4) do not need to be removed
from vacuum reservoir. (5) Remove the 4 bolts attaching battery tray (Fig.
5) to frame rail and fender shield of the vehicle.
Then remove battery tray.
(6) Remove battery acid shield, (Fig. 6) from the
ABS modulator assembly.
(7) Remove the 6 tube nuts (Fig. 7), attaching hy-
draulic brake line tube bundle to modulator assem-
bly, thread savers and proportioning valves. Then
remove the 6 hydraulic brake lines as an assembly,
from the modulator assembly. (8) Remove electrical connector from the brake
pressure differential warning switch on hydraulic
junction block (Fig. 8). (9) Remove the primary and secondary hydraulic
brake tubes (Fig. 9) going from the master cylinder
to the junction block, from both master cylinder and
junction block. (10) Remove the brake hydraulic tube going to the
vehicle's left front wheel from the junction block. (11) Remove the 6 hydraulic brake tubes at the hy-
draulic junction block, coming from the antilock mod-
ulator assembly.
Fig. 5 Battery Tray And Attaching Bolts
Fig. 6 ABS Modulator Assembly Acid Shield
Fig. 2 Battery Heat Shield And Hold Down Clamp
Fig. 3 Battery Tray Shield
Fig. 4 Speed Control System Vacuum Reservoir
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 35