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Caliper-Rear Disc Brake: Installation

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: When installing new brake components, be sure to use correct parts. Parts designed for BR4 Performance Brake System must not be mixed with other brake systems. These parts, similar in appearance, can be easily identified. (Refer to BRAKES/HYDRAULIC/MECHANICAL - DESCRIPTION - REAR DISC BRAKES) 
  1. If not already present, completely retract the caliper piston back into the piston bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
    Fig 1: Inboard Pad Installation
    GC0041090Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINER CLIP
    2 - PISTON
  2. Install the inboard brake pad into the caliper piston (2) by firmly pressing the pad in with the thumbs. Be sure the inboard brake pad is positioned squarely against the face of the caliper piston once installed.
    Fig 2: OUTBOARD PAD RETENTION TO CALIPER
    GC0041087Courtesy of DAIMLERCHRYSLER CORP.
  3. Slide the outboard brake pad (2) onto the caliper. Be sure the retaining clip (3) is squarely seated in the depressed areas on the caliper beyond the raised retaining bead (1).
    Fig 3: CALIPER INSTALLATION ON ADAPTER
    GC0041089Courtesy of DAIMLERCHRYSLER CORP.
  4. Lubricate both adapter caliper slide abutments (3, 4) with a liberal amount of Mopar® Multipurpose Lubricant or equivalent.
    CAUTION: Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter.
  5. Starting with the lower end, carefully guide the caliper (1) and brake pads over the brake rotor (2). First catch the caliper's bottom edge behind the caliper slide abutment (4), then rotate the top of the caliper into mounted position on the upper abutment (3).
    Fig 4: Rear Disc Brakes, Hub And Spindle Components
    GC0041084Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Extreme caution should be taken not to cross-thread the caliper guide pin bolts (4) when they are installed.
  6. Carefully install the caliper guide pin bolts (4). Tighten the bolts to 22 N.m (192 in. lbs.).
    Fig 5: Brake Hose Mounting
    GC0022739Courtesy of DAIMLERCHRYSLER CORP.
    1 - BANJO BOLT
    2 - GUIDE PIN BOLTS
    3 - CALIPER
    4 - BRAKE HOSE
  7. Install the banjo bolt (1) connecting the brake hose to the brake caliper. Install NEW washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 N.m (210 in. lbs.).
    Fig 6: Tire And Wheel Mounting
    GC0041085Courtesy of DAIMLERCHRYSLER CORP.
  8. Install tire and wheel assembly (1) (Refer to TIRES/WHEELS - INSTALLATION) . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  9. Lower the vehicle.
    Fig 7: Brake Pedal Holder
    GC0019697Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove the brake pedal holding tool.
    Fig 8: Bleeding Brakes
    GC0006390Courtesy of DAIMLERCHRYSLER CORP.
  11. Bleed the caliper as necessary. (Refer to BRAKES - STANDARD PROCEDURE) 
  12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
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