Chrysler DODGE D150 1993 Service Manual page 230

• BRAKES 5 - 43
CAMPER ASSEMBLY
(1) Mount caliper in vise equipped with protective
jaws. Do not overtighten vise. Excessive pressure
could cause bore distortion and piston binding.
(2) Lubricate new piston seal and piston bore with
fresh brake fluid.
(3) Install new piston seal in bore groove (Fig. 15).
Position seal in one area of groove and gently work it
around and into remainder of groove until seated. Be
sure seal is not twisted or rolled over.
Fig. 15 Installing Caliper Piston Seal
(4) Lubricate new dust boot with fresh brake fluid
and install it in caliper (Fig. 16). Work boot into
groove with fingers. Boot will seem larger t h a n
groove diameter at first but will snap into place
when properly positioned.
(5) Plug fluid inlet port and install bleeder screw.
(6) Coat caliper piston with brake fluid.
(7) Start piston into dust boot and bore (Fig. 16).
Spread dust boot with fingers. Then work piston
through boot and into bore. Air trapped below piston
will force boot around it and into groove as piston is
installed.
(8) Remove plug from inlet port and loosen bleeder
screw.
(9) Carefully press piston into bore with turning
motion until fully bottomed. Apply force uniformly to
avoid cocking piston (Fig. 16).
(10) Seat dust boot with suitable size installer tool
if necessary.
CALIPER INSTALLATION
(1) Install brakeshoes in caliper and adapter.
Fig. 16 Installing Caliper Piston
(2) Connect brake hose to brake line on frame
bracket. Tighten hose fitting to 13-20 N«m (115-175
in. lbs.) torque.
(3) Connect brake hose to caliper. Use new seal
washers when connecting fitting to caliper. Do not
tighten hose fitting at this time.
(4) Lubricate caliper and adapter slide surfaces
with Mopar high temperature grease, or an equiva­
lent grease.
(5) Install and secure caliper in adapter.
(6) Fill master cylinder and bleed brakes.
(7) Install wheel and tire assemblies and lower ve­
hicle.
ROTOR INSPECTION AND SERVICE
ROTOR CONDITION
Rotor condition and tolerances can be checked with
the rotor mounted on the axle. However, wheel bear­
ing end play should be reduced to zero before check­
ing lateral runout.
The rotor braking surfaces should not be machined
unless actually necessary. Light surface rust and
scale can be removed in a lathe equipped with dual
sanding discs.
Worn, or scored rotor surfaces can be restored by
machining in a disc brake lathe but only if surface
scoring and wear are light.
The rotor should be replaced if:
• severely scored
• tapered
• has hard spots
• cracked
• warped
• too thin
• machining would cause rotor thickness to fall be­
low minimum thickness requirements