Disc & Drum Dodge Shadow I

DISC BRAKES - FRONT

A single piston sliding caliper assembly is used on all models. The disc brake assembly consists of a caliper, disc pads, rotor and adapter (if equipped).

Monaco and Premier use double pin calipers that mount to a bolt-on adapter. All other models use one of 2 types of calipers. Kelsey-Hayes single pin or Kelsey-Hayes double pin are used. The single pin caliper uses a bolt-on adapter. The double pin caliper mounts to rails on steering knuckle.

DISC BRAKES - REAR

The single piston, floating caliper rear disc brake assembly consists of a hub assembly, caliper, disc pads, adapter, rotor and a mechanically operated parking brake.

Dynasty, Fifth Avenue, Imperial and New Yorker models use a caliper with a 1.42" (36 mm) piston. Inside the piston assembly is an automatic brake adjuster and self-adjusting parking brake mechanism. The caliper assembly rides on rubber bushings with metal sleeves on 2 bolts which mount assembly to an adapter.

Daytona and LeBaron models use calipers with a 1.30" (33 mm) piston for solid rotors (14" wheels) and a 1.42" (36 mm) piston for vented rotor (15" wheels). The parking brake mechanism consists of a small duo-servo brake in caliper mounting adapter. The center of the rotor serves as parking brake drum. The caliper assembly rides on rubber bushings, with Teflon sleeves on 2 guide pins attached to the mounting adapter.

Monaco and Premier models calipers are not serviceable and must be replaced when diagnosis indicates. The only serviceable components are: brake shoes, operating lever, lever return spring, slider pins, bushings and boots. Specifications are not available from manufacturer.

DRUM BRAKES

Rear brake system consists of a support plate, 2 brake shoes, return and hold-down spring assemblies, self-adjuster components and a wheel cylinder.

All models incorporate a self adjuster system which adjusts brakes whenever brakes are applied.

DRUM BRAKE AUTOMATIC ADJUSTER - MONACO & PREMIER

This non-servo design brake uses an incremental adjuster that adjusts during braking whenever a wear gap appears sufficient to actuate the adjuster wheel. Brake adjustment occurs during forward and rearward braking.

DRUM BRAKE AUTOMATIC ADJUSTER - EXCEPT MONACO & PREMIER

Adjuster screw thread is opposite other models. Adjuster moves upward when brakes are applied. A cage and spring on adjuster cable absorbs secondary shoe movement, except when shoe wear results in enough movement to cause adjuster to rotate. This feature reduces possibility of over-adjustment.

MASTER CYLINDER

All master cylinders are dual-piston single-bore assemblies. When brake pedal is depressed, master cylinder primary piston moves forward. Under normal conditions, combination of hydraulic pressure and force of primary piston spring, move secondary piston forward at same time.

Some master cylinders have a residual pressure valve installed under tube seat insert in drum brake outlet. This valve keeps a small amount of pressure in drum brake systems and prevents air from entering system. Many master cylinders are equipped with fluid level sensor switches and integral proportioning valves. Proportioning valves are designed to provide better front-to-rear braking balance.

BRAKE SYSTEM BLEEDING

Hydraulic system bleeding is necessary any time air has been introduced into system. Bleed brakes at all 4 wheels if master cylinder lines have been disconnected or master cylinder has run dry. Bleeding can be accomplished by using pressure bleeding equipment or by manually pumping brake pedal and using a clear bleeder hose.

SERVICING METERING VALVE

1. On disc brake equipped vehicles, the metering section of combination valve must be held open before pressure bleeding.
2. Hold metering valve open while pressure bleeding front brakes. To loosen front mounting bolt and install pressure bleeding tool on combination valve, valve stem should be fully extended or depressed. NOTE: Never reintroduce brake fluid that has been drained from hydraulic brake system or that has been allowed to stand in an open container for an extended period of time. Also, do not use fluid that contains a petroleum base. Petroleum based fluids will cause swelling and distortion of rubber parts in hydraulic system. NOTE: Bleed tubes must have a residual pressure check valves installed to keep tubes from siphoning brake fluid.
3. Clamp master cylinder in vise at mounting flange. Install bleed tubes in outlet ports. Fill reservoirs with clean brake fluid so bleed tubes are below brake fluid level. (Scheme 1)
4. Slowly compress and release piston assemblies until bubbles no longer appear in brake fluid. Remove tubes and plug master cylinder outlets to keep fluid from draining.

Scheme 1

MANUAL BLEEDING

Note. Ensure that fluid level in master cylinder is adequate at all times during bleeding procedure.

1. Fill master cylinder with clean brake fluid. Install bleeder hose to wheel assembly being serviced. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
2. Depress brake pedal slowly through its full travel and hold. Open bleed screw 3/4-1 turn. Close bleed screw. Release brake pedal. Repeat procedure until brake fluid shows no signs of air bubbles.

PRESSURE BLEEDING

1. To prevent dirt from falling into reservoir, clean master cylinder and cover/diaphragm assembly, With pressure tank at least 1/3 full, connect to master cylinder using adapters.
2. Install bleeder hose to wheel assembly being serviced. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
3. Open release valve on pressure bleeder. Open bleed screw 3/4-1 turn. Close bleed screw when brake fluid is clear and free of bubbles. Bleed remaining wheel assemblies in sequence and in same manner. Remove pressure bleeding tool.

BLEEDING PRESSURES

BLEEDING PRESSURES

BLEEDING SEQUENCE

If vehicle is equipped with power brakes, exhaust vacuum reserve from power unit by depressing brake pedal several times. Bleed master cylinder before bleeding wheel assemblies. Bleed wheel cylinders or calipers in the following sequence

BLEEDING SEQUENCE

BRAKE BOOSTER PUSH ROD

Note. Power brake units use factory adjusted or nonadjustable push rods. DO NOT attempt to adjust this type of push rod. Only Monaco and Premier specification is available from manufacturer.

Monaco & Premier

Measure push rod length from power brake unit rear face to center of push rod eye. (Scheme 2) Push rod length should be 3 3/4-3 7/8" (95-98 mm). Replace if not within specification.

Scheme 2

DISC BRAKES

Disc brakes are self-adjusting. Caliper piston seals are designed to retract pistons just enough to allow brake lining to lightly brush disc without any drag.

DRUM BRAKE SHOES - MONACO & PREMIER

Note. Adjust brakes shoes only after replacing brake lining or if brake applications are insufficient to actuate automatic adjuster.

With drum installed, rotate star adjuster through access hole on support plate to lock drum. Using a thin screwdriver and brake spoon, push adjuster lever away from star wheel and back off star wheel one complete revolution.

DRUM BRAKE SHOES - EXCEPT MONACO & PREMIER

Note. Adjust brakes shoes only after replacing brake lining or if brake applications are insufficient to actuate automatic adjuster.

1. Adjust parking brake after service brake adjustment. Remove adjusting hole covers. Insert Adjuster (C-3784), or thin-bladed screwdriver into star wheel and rotate until wheel turns with slight drag (locked on Acclaim, Horizon, Omni and Spirit).
2. On all models except Acclaim, Horizon, Omni and Spirit, back off star wheel while using welding rod to push adjusting lever (if equipped) away from star wheel. Wheels should rotate freely without drag.
3. On Acclaim, Horizon, Omni and Spirit, back off adjuster 10 clicks. On all models, adjustments must be equal on both wheels.

PARKING BRAKE - W/REAR DISC BRAKES

Note. Daytona and LeBaron models use a self-adjuster mechanism and routine parking brake adjustment is no longer necessary.

1. Raise and support vehicle. Release parking brake and loosen parking brake cable adjusting nut until cables are slack. Tightening adjusting nut until slight drag is felt while rotating rear wheels.
2. Loosen adjusting nut until rear wheels turn freely. Loosen nut an additional 2 full turns. Apply and release parking brake several times to ensure proper operation.

Scheme 3

PARKING BRAKE - W/DRUM BRAKES (MONACO & PREMIER)

Parking brake is adjusted by removing slack from cable. Cable adjustment location is under vehicle at front cable-to-rear cable junction.

PARKING BRAKE - W/DRUM BRAKES (EXCEPT MONACO & PREMIER)

1. Ensure service brakes are properly adjusted. Back off parking brake cable adjustment until it is slack. Clean and lubricate cable threads. Using Adjuster (C-3784) and a thin screwdriver inserted in brake adjusting hole to disengage adjusting lever, rotate star wheel to obtain light contact between brake shoe and drum.
2. Back off star wheel until no drag is felt. Adjust parking brake cable adjuster nut until a slight drag is felt while rotating rear wheels. Loosen adjusting nut until wheels just turn freely, then back off nut 2 full turns. Apply and release parking brake several times to ensure rear wheels DO NOT drag.

STOPLIGHT SWITCH - HORIZON & OMNI

Loosen switch assembly screw. Press brake pedal down and release. Place a .130" (3.3 mm) spacer gauge against pedal-to-switch surface. DO NOT pull brake pedal back at any time. Press switch against spacer until plunger is fully depressed. Tighten switch mounting screw, remove spacer and check switch operation.

STOPLIGHT SWITCH - ALL OTHER MODELS

1. Install switch in retaining bracket and push it forward as far as possible. Brake pedal will move slightly forward.
2. Gently pull back on pedal, bringing striker back toward switch until pedal will go no further. This will cause switch to ratchet backward to correct position.

REAR WHEEL BEARINGS

Remove dust cap, cotter pin and nut lock. Tighten bearing adjusting nut to 20-25 ft. lbs. (27-34 N.m) while rotating hub. Back off adjusting nut 1/4 turn, then tighten finger tight. Position nut lock on nut with one pair of slots in line with cotter pin hole. Install cotter pin and dust cap.

LATERAL RUNOUT - FRONT

1. To check lateral runout, install and tighten lug nuts to hold rotor on hub. Attach dial indicator to suspension so that dial pointer contacts rotor face approximately one inch from outer edge.
2. Rotate rotor and record measurement. If runout exceeds specifications, check hub lateral runout as shown. (Scheme 4)
3. Before removing rotor, chalk mark rotor and one wheel stud on high side of runout. Remove rotor and check hub runout. Runout should not exceed.003" (.08 mm).
4. If runout exceeds specification, hub must be replaced. If hub runout does not exceed specification, install the rotor on hub 180 degrees from original position. Recheck lateral runout. If runout exceeds specification, refinish or replace rotor as required.

Scheme 4

LATERAL RUNOUT - REAR

1. To check lateral runout, install and tighten lug nuts to hold rotor on hub, tighten wheel bearings until all end play is eliminated. Attach dial indicator to suspension so that dial pointer contacts rotor face approximately one inch from outer edge.
2. Rotate rotor and record measurement. If runout exceeds specifications, check hub lateral runout. (Scheme 4)
3. Before removing rotor, chalk mark rotor and one wheel stud on high side of runout. Remove rotor and check hub runout. Runout should not exceed.003" (.08 mm).
4. If runout exceeds specifications, hub must be replaced. If hub runout does not exceed specifications, install rotor on hub 180 degrees from original position. Recheck lateral runout.
5. If runout exceeds specification, refinish or replace rotor as required. Readjust wheel bearings.

PARALLELISM

To check parallelism, measure thickness of rotor at 12 points around rotor. Make all measurements one inch from edge of rotor. See DISC BRAKE ROTOR SPECIFICATIONS table at end of article. If rotor exceeds specifications, refinish or replace rotor.

DISC BRAKE PAD INSPECTION - FRONT

Inspect condition of disc pads any time wheels are removed. When disc pad linings are worn to a thickness of approximately 1/4" (6.35 mm) on Monaco and Premier models or 5/16" (7.94 mm) on all other models, they should be replaced. Some vehicles are equipped with an electronic brake lining wear sensor in the disc brake pads.

DISC BRAKE PAD INSPECTION - REAR

Inspect disc pad condition whenever wheels are removed. When a disc pad is worn to a thickness of approximately 9/32" (7.14 mm), it should be replaced.

Note. When servicing brake parts, DO NOT use compressed air during cleaning. Use water dampened shop towel to remove dust and dirt from brake parts.

Cleaning

Clean all parts except linings and drums with brake cleaning solvent. To remove brake fluid contamination, clean all parts except brake linings with denatured alcohol. Contaminated brake linings must be replaced.

Inspection

1. Pull back wheel cylinder dust boots and check for evidence of leakage. If evidence of leakage is noted, cylinder should be disassembled, inspected and overhauled. If wheel cylinders walls are badly scored, wheel cylinder must be replaced.
2. Polish brake support plate ledges with fine emery cloth. Inspect for grooves restricting shoe movement. If grooves exist after polishing, support plate must be replaced.
3. Inspect brake lining wear pattern. If wear across width of brake lining is uneven, check drum and support plate for distortion. Also ensure shoes are correctly positioned.
4. Inspect all springs for evidence of overheating and fractures. Self-adjusting cables should be inspected for kinks, fraying or spreading of cable eyelet. Check adjuster screws rotation. Inspect adjuster lever for wear and distortion. Replace all defective parts.

Removal

1. Disconnect vehicle battery. Disconnect vacuum hose at power brake unit check valve. Remove throttle cable retaining clip and move cable aside.
2. Disconnect intake hose at air cleaner and throttle body. Move hose aside for access. Remove master cylinder, proportioning valve and valve bracket. Remove bolt, nuts, spacers and bushings attaching power brake unit push rod to brake pedal.
3. Discard 2 push rod bolt nuts. Remove power brake unit-to-brake pedal bracket and dash nuts. Remove power brake unit from engine compartment.

Installation

To install, reverse removal procedure and bleed brakes. Use new push rod bolt nuts. See BRAKE SYSTEM BLEEDING in this article.

DISC BRAKE CALIPER & PADS - FRONT

Note. Both disc pad assemblies should be replaced at the same time.

1. Raise and support front of vehicle. Remove wheel and tire assembly. Remove caliper guide pin. After pin removal, use a screwdriver to pry caliper away from rotor.
2. Remove either caliper by slowly sliding it out and away from rotor. Suspend caliper with wire to prevent damage to brake hose. Remove brake pads.

1. Clean and lubricate caliper mounting adapter-to-caliper sliding contact surfaces. Remove protective paper from noise suppression gasket on pads.
2. Install inner pad on adapter and install rotor on drive hub. Install outer pad on adapter and carefully lower caliper over pads and rotor.
3. Install caliper guide pins. Tighten to specification. Pump brake pedal several times until a firm pedal is obtained. Refill master cylinder and bleed brake system if necessary.
4. Install wheel and tire assembly. Tighten lug nuts to half of torque specified, skipping every other nut while going around. When all nuts are tightened to half torque, repeat sequence, tighten to full torque. Road test vehicle.

1. Raise and support vehicle. Remove wheel and tire assembly. Release parking brake and cycle brake pedal. Manually pull caliper assembly toward outside of vehicle so that piston will be retracted.
2. Drive out disc pad retainer pin and remove 2 caliper mounting bolts. (Scheme 5) Lift caliper up and away from disc. Suspend caliper on wire hook to prevent damage to brake hose. Remove disc pads.

Scheme 5

1. Clean and lubricate caliper sliding contact areas. Install new disc pads. Carefully place caliper over disc and pads. Lower end must be installed first. Install anti-rattle clip through top opening in caliper.
2. Drive disc pad retainer pin through caliper and disc pads. Push down caliper assembly and torque upper and lower caliper mounting bolts. Install wheels and tires. Pump brakes and ensure pedal is firm. Road test and check for leaks.

Raise and support vehicle. Remove wheel and tire assembly. Remove caliper mounting bolts. Lift caliper up and away from disc. Suspend caliper on wire hook to prevent damage to brake hose. Remove disc pads. If brake fluid is present under or around caliper piston boot, caliper should be overhauled.

1. Compress piston to bottom of bore. Install inboard disc pad into caliper piston. Install outboard pad on adapter.
2. Carefully lower caliper over disc and outboard pad. Install guide pins and torque to specification. Pump brakes to ensure pedal is firm. Road test and check for leaks.

DISC BRAKE CALIPER & PADS - REAR (MONACO & PREMIER)

Note. Monaco and Premier rear calipers are not serviceable. If fluid leaks are detected around caliper piston, calipers must be replaced as an assembly.

1. Raise and support vehicle. Remove wheel and tire assembly. Unseat parking brake return spring at operating lever. Remove bolt from operating lever and mark position of lever. Remove operating lever. Remove operating lever and return spring from brake cable. Pull parking brake cable from mounting flange.
2. Remove upper caliper slide pin. Loosen lower caliper slide pin and tilt caliper rearward. Remove brake pad retaining pin with pin punch. Remove lower caliper slide pin completely and lift caliper off rotor. Remove anti-rattle spring and brake pads. Suspend caliper on wire hook to prevent damage to brake hose. Inspect all bushings and pins.

Note. Rear caliper piston must be reseated (bottomed) when installing new disc pads. Because the parking brake self-adjuster mechanism is attached to caliper piston, a different seating procedure must be followed to avoid damage to self-adjuster mechanism.

1. Reseat (bottom) caliper piston in caliper bore as follows. Remove rotor retaining nuts and rotor. Temporarily mount caliper on axle. Tighten caliper slide pins enough to hold caliper in place. Using Piston Spanner (6366), 3/8" drive extension and 7/16" deep socket, rotate piston clockwise until fully seated. (Scheme 6)
2. Remove caliper slide pins and caliper. Install rotor and retaining nuts. Position new brake pads in caliper. Rear disc pads are interchangeable.
3. Carefully lower caliper over disc and outboard pad. Install guide pins and torque to specification. Pump brakes to ensure pedal is firm. Road test and check for leaks.

Scheme 6

Raise and support front of vehicle. Remove wheel and tire assembly. Remove caliper as previously outlined. With single pin calipers, remove adapter from knuckle. Remove rotor from drive hub.

Clean both sides of rotor with alcohol or solvent. Install rotor/hub assembly on spindle. Install outer wheel bearing, thrust washer and nut. Tighten wheel bearing adjusting nut to 20-25 ft. lbs. (27-34 N.m) while rotating rotor. Back off adjusting nut to release preload. Retighten adjusting nut finger tight. Install nut lock, cotter pin and grease cup. To complete installation, reverse removal procedure.

Scheme 7

Scheme 8

1. Release brake adjustment. Remove grease cap, cotter pin, lock nut and washer. Remove brake drum and bearings. Remove parking brake cable, shoe anchor springs and hold-down springs. Spread shoes and remove adjuster assembly. (Scheme 7)or (Scheme 8).
2. Remove brake shoes by raising parking brake lever. Pull shoe away from support to remove spring tension and disengaging spring from support. Remove springs from brake shoes.

1. Install primary shoe return spring. Install primary shoe while engaging return spring end in support and shoe end under anchor plate. Install secondary shoe and spring in same manner. Spread shoes and install adjuster assembly with 2 stepped forks facing toward outboard side of shoes. Longer fork will be pointing to rear.
2. Install hold-down pins, springs and anchor springs. Compress parking brake cable housing spring to expose cable. Slide cable into parking brake lever. Position washer between parking brake cable housing spring and parking brake lever.
3. Install drum, bearing, washer, nut. While rotating hub and drum assembly, tighten wheel bearing nut to 20-25 ft. lbs. (27-34 N.m). Loosen wheel bearing nut to relieve all preload from bearing. Finger tighten wheel bearing nut. End play should be .001-.003" (.025-.076 mm).
4. Install cotter pin and grease cap. Bleed brakes and check for proper brake operation before moving vehicle.

1. Remove wheel and tire assembly. Remove grease cap from hub and drum assembly. Remove wheel bearing lock nut. Remove drum and hub assembly as a unit, being careful not to drag seal across spindle threads.
2. Remove upper return spring. Remove adjuster lever spring. Remove hold-down spring and pins. Lift brake shoe and adjuster assembly off support plate. Install wheel cylinder cup retainer. Remove parking brake cable from parking brake lever. Remove parking brake lever from rear shoe.

Scheme 9

1. Lubricate all brake shoe contact points, adjusting assembly, parking brake lever and lever pivot pin. Remove retaining clamp from wheel cylinder. Install parking brake lever on secondary shoe.
2. Install washer and new clip on parking brake lever pivot pin and crimp ends of clip. Install rear brake shoe to support plate. Install hold down spring. Install adjuster screw and rear brake shoe making sure large notch on adjuster screw is fitted to brake shoe and small notch on adjuster screw is facing out.
3. Install adjuster lever to leading shoe adjuster lever pivot pin and fit adjuster lever into smallest of 2 notches on adjuster screw. Install upper spring. Center shoes on support plate. Install brake drum and hub assembly. Install new wheel bearing lock nut and lightly tighten. Adjust brakes. Tighten new wheel bearing lock nut to 123 ft. lbs. (167 N.m).

1. On power brake systems, disconnect brake fluid level indicator and brake warning switch leads (if equipped). Disconnect hydraulic brake lines. Remove master cylinder attaching nuts and remove master cylinder.
2. On manual brake systems, disconnect negative battery cable and fluid level sensor switch connector (if equipped). Disconnect hydraulic brake lines. Remove push rod at brake pedal and remove stoplight switch. Remove master cylinder attaching nuts and remove master cylinder.

1. Bench bleed master cylinder. See BENCH BLEEDING MASTER CYLINDER under BRAKE SYSTEM BLEEDING in this article. To complete installation, reverse removal procedure. Bleed hydraulic brake system. See BRAKE SYSTEM BLEEDING in this article.
2. Check master cylinder compensating ports. Remove master cylinder cover and observe brake fluid. Have an assistant press brake pedal. A small spurt should appear in one or both reservoirs. If no spurt appears, push rod may be improperly adjusted.
3. On manual brakes, adjust push rod at brake pedal. Push rod should have a slight amount of play when brake pedal is released. On power brakes, push rod is non-adjustable.

DISC BRAKE CALIPER - FRONT

Disassembly (Except Monaco & Premier)

1. With caliper removed from rotor and brake hose still attached, carefully depress brake pedal to hydraulically force piston out of bore. If both pistons are to be removed, disconnect flexible brake line at frame bracket after removing first piston. Plug brake tube and repeat procedure.
2. Disconnect brake hose from caliper. Place caliper in vise and remove dust boot. Using a small wooden or plastic stick, pry piston seal from caliper bore groove. Remove bushings from calipers.

Disassembly (Monaco & Premier)

Remove caliper as previously described. Disconnect brake hose from caliper. Place a piece of wood in caliper and apply air to brake hose bore to remove piston. Remove dust boot. Using a small wooden or plastic stick, pry piston seal from caliper bore groove.

Cleaning & Inspection

Clean all components (including bleeder screw) using alcohol or solvent. Blow out all passages and bores with compressed air. Inspect piston and bore for scoring or pitting. On Monaco and Premier models, replace caliper and piston if scored. On all other models, clean light scoring or corrosion with crocus cloth. Bores with deep scoring may be honed, providing diameter of bore is not increased more than .001" (.025 mm). If specification is exceeded, replace caliper.

Reassembly

1. Dip new piston seal in clean brake fluid and gently work seal into groove until seated. Coat new piston boot with clean brake fluid, leaving a generous amount inside boot.
2. Position dust boot over piston. Install piston, pushing it past seal until it bottoms in bore. Position boot in counterbore. Using a hammer and dust boot installer, drive boot into counterbore.
3. Install new bushings on caliper by pressing in on bushings until seated. Be sure that bushing flanges extend evenly over caliper casting. Clean and lubricate caliper mounting adapter-to-caliper sliding contact surfaces.

Scheme 10

DISC BRAKE CALIPER - REAR (MONACO & PREMIER)

Rear calipers are not serviceable. If fluid leaks are detected around caliper piston, calipers must be replaced as an assembly.

Disassembly

1. With caliper removed from rotor and brake hose still attached, carefully depress brake pedal to hydraulically force piston out of bore. If both pistons are to be removed, disconnect flexible brake line at frame bracket after removing first piston. Plug brake tube and repeat procedure.
2. Disconnect brake hose from caliper. Place caliper in vise and remove dust boot. Using a small wooden or plastic stick, pry piston seal from caliper bore groove. Remove bushings from calipers. Discard bushings and Teflon sleeves.

Clean all components (including bleeder screw) using alcohol or solvent. Blow out all passages and bores with compressed air. Inspect piston and bore for scoring or pitting. Clean light scoring or corrosion with crocus cloth. Bores with deep scoring may be honed, providing diameter of bore is not increased more than .001" (.025 mm). If specification is exceeded, replace caliper.

1. Dip new piston seal in clean brake fluid and gently work seal into groove until seated. Coat new piston boot with clean brake fluid, leaving a generous amount inside boot.
2. Position dust boot over piston. Install piston, pushing it past seal, until it bottoms in bore. Position boot in counterbore. Using a hammer and dust boot installer, drive boot into counterbore.
3. Install new bushings on caliper by pressing in on bushings until seated. Ensure bushing flanges extend evenly over caliper casting. Clean and lubricate caliper-to-mounting bracket contact areas. Install caliper. Fill and bleed system. Check brake operation.

Dust Boot Removal Installation

1. Clean caliper with alcohol or solvent. Using a screwdriver, remove dust boot. Dip new dust boot in clean brake fluid.
2. On Dynasty, Fifth Avenue, Imperial and New Yorker, position boot over piston and use Dust Boot Installer (C-4383-7) to seat boot into caliper.
3. On Daytona and LeBaron calipers, position boot over piston and install retainer to hold boot to caliper.

Bushing & Sleeve Removal & Installation

Remove old sleeve and bushing from caliper. Clean caliper with alcohol or solvent. Compress new bushings with fingers and work into proper position. Insert new sleeves. Ensure bushing is seated in sleeve grooves.

1. Clean outside of master cylinder. Remove caps or cover diaphragm assembly. Remove brake fluid level indicator (if equipped). Pump and drain all brake fluid from master cylinder. Clamp master cylinder in vise at mounting flange. Remove plastic reservoir and grommets on 2-piece master cylinders.
2. Press primary piston inward and remove stop bolt or snap ring. Remove primary piston assembly. Apply compressed air to furthest back bleeder screw hole and remove secondary piston assembly.

1. Wash master cylinder body, bore and piston assemblies with denatured or isopropyl alcohol. Inspect piston assemblies and return springs. Replace pistons if scored, worn, cracked or broken. Replace springs if they are broken, bent, collapsed, distorted or fatigued.
2. Inspect tube seat inserts in outlet ports. Replace if they are cracked, scored, loose, cocked or worn. If removal kits are not available, replace by using spiral easy-out.
3. Remove check valve and spring from drum brake outlet (if equipped). Inspect cylinder bore for scoring, corrosion or wear. Aluminum master cylinders are anodized. Wear on the anodized surface, as evidenced by lighter areas, is normal.
4. DO NOT polish aluminum master cylinders. Aluminum master cylinders must be replaced if cylinder bore is damaged. On cast iron master cylinders, use crocus cloth to polish light corrosion. Replace master cylinder if bore does not clean using crocus cloth.
5. Inspect compensator and by-pass ports at bottom of reservoir. If they are plugged or dirty, clean them using brake cleaning solvent and compressed air.

1. Install check valve and spring in drum brake outlet (if removed). Using a spare tubing nut, press tube seat insert into place (if removed). Turn nut until tube seat insert bottoms. Remove nut and inspect outlet for burrs or shavings.
2. Coat bore of cylinder and piston assemblies with clean brake fluid. Install secondary and primary piston assemblies into bore. Press primary piston inward and install snap ring or stop bolt. Install push rod (if equipped).
3. On 2-piece master cylinders, lubricate grommets with clean brake fluid and install in master cylinder. Ensure grommets are properly seated. Place reservoir on hard surface and install plastic reservoir with a rocking motion.
4. Fill reservoir with clean brake fluid and bleed master cylinder. See BENCH BLEEDING MASTER CYLINDER under BRAKE SYSTEM BLEEDING in this article.

Scheme 11

ALL EXCEPT MONACO & PREMIER

TORQUE SPECIFICATIONS (ALL EXCEPT MONACO & PREMIER)

TORQUE SPECIFICATIONS (MONACO & PREMIER)

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DRUM BRAKE SYSTEM SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS