Front

DISASSEMBLY

NOTE: Before disassembling caliper, clean and inspect it. Disc Brake Caliper - Cleaning Front

1. Remove front disc brake caliper from vehicle. Disc Brake Caliper - Removal.
2. If brake pads were not removed from caliper prior to removing caliper from vehicle, remove brake pads. Brake Pads - Removal.









3. Remove transfer brake tube (2) between inboard and outboard caliper halves.










4. Install M10 X 1.0 threaded plug (2) in flex hose banjo bolt hole. This hole needs to be plugged to remove caliper inboard pistons using compressed air.










5. Install C-clamp (2) over inboard caliper piston nearest to bleeder screw (4) as follows:
a. Lay shop towel (3) over outside of inboard caliper half to protect finish.
b. Place Installer (5), Special Tool 6454, over piston and boot nearest to bleeder screw and hold in place. Either side of Installer will work.
c. Place C-clamp (2) over tool and towel as shown and tighten C-clamp. DO NOT USE EXCESSIVE FORCE; excessive force could damage caliper or piston.

6. Place an appropriate size block of wood inside center area of caliper, in front of first piston to be removed. Block of wood should be large enough to allow piston to exit piston bore just far enough for piston to be pulled out remaining distance by hand, but not exit the bore completely.

WARNING: Do not place face or hands near pistons or into center area of caliper when using compressed air to remove pistons from bore of caliper. Personal injury can result from such action.

WARNING: Under no conditions should high pressure air be used to remove piston from caliper bore. Personal injury can result from such action.

7. Using a rubber tipped air nozzle, apply short bursts of low pressure compressed air to caliper transfer port to force piston from bore.

8. Remove block of wood from center area of caliper.
9. Remove piston from caliper bore, but leave piston dust boot in place.









10. Move C-clamp (3), shop towel (5) and Installer (2) to cover piston boot and bore where piston was just removed. It may be necessary to place a small piece of rubber over hole in center of Installer to seal off empty bore.
11. Place block of wood (1) inside center area of caliper, in front of second piston to be removed.
12. Using a rubber tipped air nozzle (4), apply short bursts of low pressure compressed air to caliper transfer port to force piston from bore.
13. Remove block of wood from center area of caliper.
14. Remove piston from caliper bore.
15. Remove C-clamp and Installer.










16. Remove piston dust boots (1) from empty piston bores of caliper. To do so, carefully pry each boot from its retaining groove (2) using a small screwdriver or other suitable tool. The screwdriver must be inserted between outer edge of dust boot and caliper. Do not insert screwdriver into bore of caliper to remove boot; scoring of bore may occur.










17. Remove piston seal (1) from each empty piston bore using a trim stick (2) or other suitable tool that will not score the piston bore. Do not use a screwdriver or other metal tool; scoring of bore or burring of seal groove may occur.
18. Remove bleeder screw from inboard half of caliper.










19. Remove threaded plug (2) from banjo bolt hole in inboard half of caliper.










20. Install C-clamp over outboard caliper piston nearest to bleeder screw as follows:
a. Lay shop towel (3) over outside of outboard caliper half to protect finish.
b. Place Installer (4), Special Tool 6454, over piston and boot nearest to bleeder screw and hold in place. Either side of Installer will work.
c. Place C-clamp (2) over tool and cloth as shown and tighten C-clamp. DO NOT USE EXCESSIVE FORCE; excessive force could damage caliper or piston.
21. Place an appropriate size block of wood (1) inside center area of caliper, in front of piston nearest transfer tube port. Block of wood should be large enough to allow piston to exit piston bore just far enough for piston to be pulled out remaining distance by hand, but not exit the bore completely.

WARNING: Do not place face or hands near pistons or into center area of caliper when using compressed air to remove pistons from bore of caliper. Personal injury can result from such action.

WARNING: Under no conditions should high pressure air be used to remove piston from caliper bore. Personal injury can result from such action.

22. Using a rubber tipped air nozzle, apply short bursts of low pressure compressed air to caliper transfer port to force piston from bore.
23. Remove block of wood from center area of caliper.
24. Remove piston from caliper bore, but leave piston dust boot in place.









25. Move C-clamp (2), shop towel (3), and Installer (4) to cover piston boot and bore where piston was just removed. It may be necessary to place a small piece of rubber over hole in center of Installer to seal off empty bore.
26. Place the piece of wood (1) inside center area of caliper, in front of piston to be removed.
27. Using a rubber tipped air nozzle, apply short bursts of low pressure compressed air to caliper transfer port to force piston from bore.
28. Remove piece of wood from center area of caliper.
29. Remove piston from caliper bore.
30. Remove C-clamp and Installer.










31. Remove piston dust boots (1) from empty piston bores of outboard half of caliper. To do so, carefully pry each boot from its retaining groove (2) using a small screwdriver or other suitable tool. The screwdriver must be inserted between outer edge of dust boot and caliper. Do not insert screwdriver into bore of caliper to remove boot; scoring of bore may occur.










32. Remove piston seal (1) from each empty piston bore of outboard half of caliper using a trim stick (2) or other suitable tool. Do not use a screwdriver or other metal tool; scoring of bore or burring of seal groove may occur.
33. Remove bleeder screw on outboard half of caliper.

34. Thoroughly clean each of the four pistons using Mopar(R) Non-Clorinated Brake Parts Cleaner, alcohol or other suitable solvent and wipe dry using a lint free towel. Inspect all surfaces of each piston for any signs of corrosion or scoring. If any corrosion on piston cannot be removed using these products, or if piston is scored, replace piston. Do not sand piston to remove corrosion or scoring.

CAUTION: Do not attempt to hone piston bores of this caliper. If bores cannot be cleaned using appropriate solvents, caliper must be replaced.

35. Clean piston bores of caliper using Mopar(R) Non-Clorinated Brake Parts Cleaner, alcohol or another suitable solvent saturated into a lint free towel. Once thoroughly cleaned, wipe each bore dry using a clean lint free towel. Inspect all surfaces inside caliper bores for any signs of corrosion or scoring. If any corrosion inside piston bores cannot be removed using these products, or if any bore is scored, the caliper assembly must be replaced.
36. Blow out piston bores of caliper to remove any particles that may be left from cleaning procedure and to ensure bore is dry.
37. Proceed to Assembly to assemble caliper. Disc Brake Caliper - Assembly