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Home >> Chrysler >> 2003 >> Intrepid ES, 3.5 V >> Repair and Diagnosis >> External Pages >> Different car >> Section 8 (Disc Brakes) >> Removal & Installation >> Caliper >> Installation (Front)

Installation (Front)

WARNING: This page is about a different car, the 2002 Dodge Intrepid, 2002 Chrysler Intrepid, 2002 Chrysler Concorde, and 2002 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Use care when installing the caliper assembly on the steering knuckle, so seals on caliper guide pin bushings do not get damaged by the steering knuckle bosses.
  1. Completely retract caliper piston back into the piston bore of caliper.
  2. If removed, install brake rotor onto hub. See ROTOR  .
  3. Lubricate both machined knuckle abutments with a liberal amount of Mopar(R) Brake Grease For Caliper Slides Lubricant, or equivalent.
  4. Install one rail shim on each machined abutment where it will contact the brake shoes. Make sure the alignment tabs on the shims are positioned toward the abutments.
  5. Carefully position caliper and brake shoes over rotor by reversing removal procedure.
    6. CAUTION: During installation, extreme caution should be taken not to cross-thread the caliper guide pin bolts.
  6. Install the caliper guide pin bolts. See TORQUE SPECIFICATIONS  .
  7. 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 the banjo bolt to specification. See TORQUE SPECIFICATIONS  .
  8. Install the wheel and tire assembly. See TORQUE SPECIFICATIONS  .
  9. Lower vehicle.
    10. CAUTION: After performing any service to the vehicle brake system, be sure to obtain a firm brake pedal before moving vehicle.
  10. Remove the brake pedal holding tool.
  11. Bleed the brake system. See BLEEDING PROCEDURE  under BLEEDING BRAKE SYSTEM.
  12. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.
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