Chrysler Concorde 2004 Service Manual page 1500

5 - 34 BRAKES - BASE BRAKE SYSTEM
DISC BRAKE CALIPER - REAR (Continued)
(4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 55).
Fig. 55 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
(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. 56).
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
INSTALLATION- REAR CALIPER
NOTE: Step 1 below is only required when installing
the disc brake caliper after new brake shoes have
been installed.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments with a lib-
eral amount of Mopar
equivalent.
(3) Install the rear rotor on the hub, making sure
it is squarely seated on the face of the hub (Fig. 43).
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.
Multipurpose Lubricant, or
Fig. 56 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
(4) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 41).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(5) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 22 N·m (192 in. lbs.).
(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.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoe linings.
LH