Installation; Disc Brake Caliper Guide Pins Removal - Chrysler PT Cruiser Service & Repair Manual

5 - 34 BRAKES - BASE
DISC BRAKE CALIPER ADAPTER - FRONT (Continued)
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 62).
Fig. 62 Brake Caliper Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
(4) Remove the disc brake caliper from the
adapter. Hang the caliper out of the way using wire
or a bungee cord. Use care not to overextend the
brake hose when doing this.
(5) Remove the brake shoes from the disc brake
caliper adapter (Fig. 63).
Fig. 63 Brake Shoes Mounted In Adapter
1 - SPRINGS
2 - INBOARD SHOE
3 - OUTBOARD SHOE
4 - DISC BRAKE ADAPTER
5 - ABUTMENT SHIMS
6 - BRAKE ROTOR
(6) Remove the abutment shims from the adapter
(Fig. 63).
(7) Remove the two bolts securing the disc brake
caliper adapter to the steering knuckle (Fig. 62).
(8) Remove the disc brake caliper adapter.

INSTALLATION

CAUTION: When installing new brake components,
be sure to use correct parts. Parts designed for
BR4 Performance Brake System must not be mixed
with other brake systems. These parts, similar in
appearance, can be easily identified (Fig. 11) (Fig.
12).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL
- DESCRIPTION - DISC BRAKES (FRONT))
(1) Install the disc brake caliper adapter on the
steering knuckle.
(2) Install the two bolts securing the disc brake
caliper adapter to the steering knuckle (Fig. 62).
Tighten the bolts to a torque of 104 N·m (77 ft. lbs.).
(3) Attach the two abutment shims to the adapter
fitting the contour of each shim to the adapter's con-
tour (Fig. 63).
(4) Place the brake shoes in the abutment shims
clipped into the disc brake caliper adapter as shown
(Fig. 63). Place the shoe with the wear indicator
attached on the inboard side.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(5) Install the disc brake caliper over the brake
shoes on the brake caliper adapter. Make sure the
springs on the shoes do not get caught in the hole
formed into the center of the caliper housing.
(6) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
62).
(7) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(8) Lower the vehicle.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
DISC BRAKE CALIPER GUIDE
PINS
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
PT