Chrysler 1997 Stratus Convertible RHD Service Manual page 159

JX
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 159 Correctly Installed Caliper Sleeve And
(2) Carefully depress brake pedal to hydrauli-
cally push piston out of bore. Then apply and hold
down the brake pedal to any position beyond 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 brake tube at flexible brake hose at frame
rail. Plug brake tube and remove piston from oppo-
site caliper using the same process as above for the
first piston removal.
(4) Disconnect the brake fluid flex hose from the
caliper assembly.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
(5) To disassemble caliper, mount in a vise
equipped with protective jaws.
(6) Remove guide pin sleeves and guide pin bush-
ings. See Removing Guide Pin Bushings in the cali-
per disassembly section of this manual.
(7) Remove the piston dust boot from the caliper
and discard (Fig. 160).
(8) Using a soft tool, such as a plastic trim stick,
work piston seal out of its groove in caliper piston
bore (Fig. 161). Discard old seal. Do not use a
screw driver or other metal tool for this opera-
tion, because of the possibility of scratching
piston bore or burring edges of seal groove.
(9) Clean all parts using alcohol or a suitable sol-
vent and wipe dry using only a lint free cloth. No
Bushing
PISTON SEAL
Fig. 160 Removing Caliper/Piston Dust Boot
Fig. 161 Removing Piston Seal From Caliper
lint residue can remain in caliper bore. Clean out all
drilled passages and bores. Whenever a caliper
has been disassembled, a new boot and seal
must be installed at assembly.
(10) 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. Bores that have deep scratches or
scoring should be honed. Use Caliper Hone, Special
Tool C-4095, or equivalent providing the diameter of
BRAKES
PLASTIC TRIM STICK PISTON SEAL GROOVE
5 - 57
CALIPER