Chrysler PT Cruiser Service & Repair Manual page 137

PT
DISC BRAKE CALIPER - REAR (Continued)
Fig. 50 Removing Bushing From Caliper
1 - CALIPER
2 - BUSHING
(1) Following the removal procedure in DISC
BRAKE SHOES (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - REMOVAL),
remove the caliper from the brake rotor and hang the
assembly on a wire hook away from rotor and body of
the vehicle so brake fluid cannot get on these compo-
nents. Remove the brake shoes, and place a small
piece of wood between the piston and caliper fingers.
(2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out.
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CALIPER SEAL REMOVAL
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(1) To disassemble the caliper, mount it in a vise
equipped with protective jaws.
(2) Remove the piston dust boot from the caliper
and discard (Fig. 51).
Fig. 51 Removing Caliper/Piston Dust Boot
1 - CALIPER
2 - SCREWDRIVER
3 - BOOT
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(3) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 52). Discard the old seal.
(4) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(5) 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 the equivalent to hone the bore. Do
not over-hone the bore. Don not increase the diame-
ter of the bore more than 0.0254 mm (0.001 inch)
(Fig. 53). If the bore does not clean up within this
specification, a new caliper housing should be
installed.
NOTE: During the honing procedure, coat the
stones and bore with brake fluid. After honing the
bore, carefully clean the seal and boot grooves with
a stiff non-metallic rotary brush. Use extreme care
in cleaning the caliper after honing. Remove all dirt
and grit by flushing the caliper bore with fresh
clean brake fluid; wipe it dry with a clean, lint free
cloth and then clean it a second time.
BRAKES - BASE 5 - 29