2001 CHRYSLER VOYAGER warning

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 67
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION............................2
OPERATION.............................2
WARNING...............................3
CAUTION................................3
DIAGNOSIS AND TESTING..................3
BASE BRAKE SYSTEM...................3
STANDARD PROCEDURE...................6
BASE BRAKE BLEEDING..................6
SPECIFICATIONS.........................8
SPECIAL TOOLS..........................8
BRAKE FLUID LEVEL SWITCH
DESCRIPTION............................9
OPERATION.............................9
REMOVAL...............................9
INSTALLATION............................9
HYDRAULIC/MECHANICAL
DESCRIPTION...........................10
OPERATION.............................12
DIAGNOSIS AND TESTING.................12
DRUM BRAKE AUTOMATIC ADJUSTER......12
BRAKE LINES
DESCRIPTION...........................13
OPERATION.............................13
INSPECTION............................13
BRAKE PADS/SHOES - FRONT
REMOVAL..............................13
CLEANING..............................14
INSPECTION............................14
INSTALLATION...........................15
BRAKE PADS/SHOES - REAR DISC
REMOVAL..............................15
CLEANING..............................17
INSPECTION............................17
INSTALLATION...........................17
BRAKE PADS/SHOES - REAR DRUM
REMOVAL..............................18INSPECTION............................20
INSTALLATION...........................21
ADJUSTMENTS..........................22
DISC BRAKE CALIPERS - FRONT
REMOVAL..............................22
DISASSEMBLY...........................23
CLEANING..............................24
INSPECTION............................24
ASSEMBLY.............................24
INSTALLATION...........................25
DISC BRAKE CALIPERS - REAR
REMOVAL..............................26
DISASSEMBLY...........................27
CLEANING..............................28
INSPECTION............................28
ASSEMBLY.............................28
INSTALLATION...........................29
DISC BRAKE CALIPER ADAPTER
REMOVAL..............................29
INSTALLATION...........................29
DISC BRAKE CALIPER GUIDE PINS
REMOVAL..............................30
INSTALLATION...........................30
DRUM
STANDARD PROCEDURE..................31
BRAKE DRUM MACHINING...............31
REMOVAL..............................31
INSTALLATION...........................31
FLUID
DIAGNOSIS AND TESTING.................31
BRAKE FLUID CONTAMINATION...........31
STANDARD PROCEDURE..................32
BRAKE FLUID LEVEL CHECKING..........32
SPECIFICATIONS........................32
RSBRAKES5-1

disc/drum brakes or drum-in-hat for disc/disc brakes)
and hold it in place.
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN 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 CON-
TAIN 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 CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL 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.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
rotor or drum, and external surfaces of hub and
bearing assembly.
CAUTION: Handling of brake rotors and calipers
must be done in such a way as to avoid damage to
the rotor and scratching or nicking of brake lining
on the brake shoes.
CAUTION: At no time when servicing a vehicle, can
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled
into the front shock tower in the area shown in (Fig.1), for the installation of any metal fasteners into
the shock tower. Because of the minimum clear-
ance in this area (Fig. 1), installation of metal fas-
teners could damage the coil spring coating and
lead to a corrosion failure of the spring. If a plastic
clip is missing, or is lost or broken during servicing
a vehicle, replace only with the equivalent part
listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
1 - SHOCK TOWER
2 - COIL SPRING
3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER
METAL FASTENERS ARE TO BE INSTALLED INTO SHOCK
TOWER IN THIS AREA. ALSO, NO HOLES ARE TO BE DRILLED
INTO SHOCK TOWER IN THIS SAME AREA.
RSBRAKES - BASE5-3
BRAKES - BASE (Continued)

RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated.6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage.2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK1. Broken or missing anti-rattle
spring clips on shoes.1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING1. ABS wheel speed sensor or tone
wheel.1. Inspect, correct or replace faulty
component(s).
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)

BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 4).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:
²Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system.
²Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid.If
the brake fluid level has dropped below the add
line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 4).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch.
(3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.
(2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 4).
Tubes, Master Cylinder Bleed 8358
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Safe-Set
Handle, Universal C±4171
Installer, Dust Boot C-4689 or C-4842
RSBRAKES - BASE5-9
BRAKES - BASE (Continued)

REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
NOTE: Perform Step 2 through Step 5 on each side
of the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 14).
(4) Remove the disc brake caliper from the disc
brake adapter and hang out of the way using wire or
a bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove the brake shoes from the disc brake
caliper adapter.
CLEANING - DISC BRAKE SHOES
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN 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 CON-
TAIN 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 AFINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL 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.
INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors.
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers.
Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point.
²For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.
²For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced.
Replacebothdisc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
Fig. 13 Removing Inboard Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
Fig. 14 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5 - 14 BRAKES - BASERS
BRAKE PADS/SHOES - FRONT (Continued)

CLEANING - DISC BRAKE SHOES
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN 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 CON-
TAIN 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 CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL 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.
INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors.
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers.
Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point.
²For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.
²For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced.
Replacebothdisc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were remove from.
INSTALLATION - REAR DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments where the
shoes contact with a liberal amount of MopartMul-
tipurpose Lubricant, or equivalent.
(3) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
(5) Install the outboard brake shoe on the disc
brake caliper. Be sure the outboard shoe is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(6) Carefully lower caliper and brake shoes over
rotor and onto adapter, reversing the removal proce-
dure (Fig. 16).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
(8) Install the wheel and tire assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification. Then repeat
the tightening sequence to the full specified torque of
135 N´m (100 ft. lbs.).
(9) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(10) Pump brake pedal several times to set brake
shoes to rotors.
(11) Check fluid level in reservoir.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
RSBRAKES - BASE5-17
BRAKE PADS/SHOES - REAR DISC (Continued)

DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING or INSPECTION in
this section.
(1) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss.
(2) Repeat this procedure on the remaining bush-
ing.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers.
(2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out.
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.(4) Mount the caliper in a vise equipped with pro-
tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 33). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.
Fig. 33 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
RSBRAKES - BASE5-23
DISC BRAKE CALIPERS - FRONT (Continued)

CLEANING - CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN 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 CON-
TAIN 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 CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL 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 MopartNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
²Brake fluid leaks in and around boot area and
inboard lining
²Ruptures, brittleness or damage to the piston
dust boot
²Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
(DISC/DISC BRAKES)
(1) Fold the guide pin bushing in half lengthwise.
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
(2) Insert the folded bushing into the caliper
mounting boss using your fingers from the rear of
the caliper.
(3) Unfold the bushing using your fingers or a
wooden dowel until the bushing is fully seated intothe caliper housing. The bushing flanges should be
seated evenly on both sides of the bushing hole.
(4) Lubricate inside surfaces of bushing using
MopartDielectric Grease or equivalent.
(5) Repeat the procedure for remaining bushing.
ASSEMBLY - CALIPER PISTON AND SEAL
NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid
and install it in the groove of the caliper bore. The
seal should be started at one area of the groove and
gently worked around and into the groove (Fig. 34)
using only your clean fingers to seat it.
(2) Coat the new piston boot with clean brake
fluid.
(3) Position the dust boot over the piston after
coating it with brake fluid.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 35).
(5) Position the dust boot into the counterbore of
the caliper assembly piston bore.
(6) Using a hammer and Installer, Special Tool
C-4689 or C-4842 (depending on piston size), and
Handle, Special Tool C-4171, drive the boot into the
counterbore of the caliper as necessary (Fig. 36).
Fig. 34 Installing New Piston Seal
1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
5 - 24 BRAKES - BASERS
DISC BRAKE CALIPERS - FRONT (Continued)