Chrysler neon 1997 Service Manual page 103

CALIPER ASSEMBLY GUIDE STEERING DISC BRAKE CALI- PER ASSEMBLY KNUCKLE PIN BOLTS BRAKING DISC
5 - 26 BRAKES
REMOVAL AND INSTALLATION (Continued)
FRONT DISC BRAKE CALIPER
REMOVE
During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the braking rotor and caliper should
be done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this service manual for the required
lifting procedure for this vehicle.
(2) Remove the front wheel and tire assemblies
from this vehicle.
(3) Remove the 2 brake caliper to steering knuckle
guide pin bolts (Fig. 54).
Fig. 54 Caliper Guide Pin Bolts
(4) Remove caliper from steering knuckle, by first
rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
55).
(5) Support the disc brake caliper firmly using a
wire hanger (Fig. 56). This is required to prevent the
weight of the caliper from damaging the flexible
brake hose .
INSTALL
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Completely retract the caliper piston back into
the bore of the caliper.
(2) Lubricate both steering knuckle abutments
with a liberal amount of Mopar Multipurpose Lubri-
cant, or equivalent.
(3) If removed, install the front rotor on the hub,
making sure it is squarely seated on face of hub.
DRIVESHAFT LOWER CONTROL ARM AWAY LIFT THIS END OF CALIPER PER FROM UNDER STEER- SLIDE THIS END OF CALI- WIRE HANGER DISC BRAKE CALIPER DISC BRAKE CALIPER FROM KNUCKLE FIRST ING KNUCKLE ASSEMBLY STEERING ROTOR
Fig. 55 Removing Caliper Assembly From Steering
Fig. 56 Storing Disc Brake Caliper
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(4) Carefully position the brake caliper and brake
shoes on the steering knuckle by first hooking the
end of the caliper under the edge of the steering
knuckle as shown in (Fig. 57). Then rotate caliper
into position on the steering knuckle.
(5) Install the caliper guide pin bolts and tighten
to 18 to 20 N·m (192 in. lbs.) (Fig. 54). Extreme
caution should be taken not to cross thread the
caliper guide pin bolts.
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud 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.).
(8) Remove jackstands or lower hoist. Before mov-
ing vehicle, pump the brake pedal several times to
insure the vehicle has a firm brake pedal.
BRAKE HYDRAULIC HOSE STEERING KNUCKLE
Knuckle
BRAKE DISC
PL