Intrepid V6-2.7L VIN R (2003)
1. Completely retract the caliper piston back into the piston bore of the caliper.
2. If removed, install brake rotor on hub.
3. Lubricate both machined knuckle abutments with a liberal amount of Mopar Brake Grease For Caliper Slides Lubricant, or equivalent.
4. Install one rail shim on each machined abutment where it will contact the brake shoes. Make sure the alignment tabs on the shims are positioned
toward the abutments.
5. Carefully position caliper and brake shoes over rotor by reversing removal procedure.
CAUTION: When being installed, extreme caution should be taken not to crossthread the caliper guide pin bolts.
6. Install the caliper guide pin bolts. Tighten guide pin bolts to a torque of 22 Nm (192 inch lbs.).
7. Install the banjo bolt connecting the flex hose to the caliper. One washer should be installed on each side of the flex hose fitting before installing
the banjo bolt. Tighten banjo bolt to a torque of 48 Nm (35 ft. lbs.).
8. Install the wheel and tire assembly.
9. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 135 Nm (100 ft. lbs.).
10. Lower vehicle.
CAUTION: After performing any service to the vehicle brake system, be sure to obtain a firm brake pedal before moving vehicle.
11. Remove the brake pedal holding tool.
12. Bleed the base brakes.
13. Road test the vehicle and make several stops to wear off any foreign material off the brakes and to seat the brake shoe linings.
Removal and Installation - Export
REMOVAL - FRONT CALIPER (EXPORT)
1. Using a brake pedal holding tool, depress brake pedal past its first 1 inch of travel and secure in this position. This will isolate the master cylinder
reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.
2. Raise vehicle.
3. Remove front wheel and tire assembly from vehicle.
4. Remove the banjo bolt connecting the brake flex hose to the caliper. There will be two washers (one on each side of the flex hose fitting) that will
come off at the same time.
5. Remove the two caliper guide pin bolts.
6. Remove caliper assembly from steering knuckle. Proceed by first rotating top of caliper away from steering knuckle and then lifting caliper off
bottom machined abutment on steering knuckle.
7. If required, remove rotor from hub by pulling it straight off wheel mounting studs.
INSTALLATION - FRONT CALIPER (EXPORT)
CAUTION: Use care when installing the caliper assembly on the steering knuckle, so seals on caliper guide pin bushings do not get damaged by the
steering knuckle bosses.
1. Completely retract the caliper piston back into the piston bore of the caliper.
2. If removed, install brake rotor on hub.
3. Lubricate both machined knuckle abutments with a liberal amount of Mopar Brake Grease For Caliper Slides Lubricant, or equivalent.
4. Carefully position caliper and brake shoes over rotor by reversing removal procedure .
CAUTION: When being installed, extreme caution should be taken not to crossthread the caliper guide pin bolts.
5. Install the caliper guide pin bolts. Tighten guide pin bolts to a torque of 22 Nm (192 inch lbs.).
6. Install the banjo bolt connecting the flex hose to the caliper. One washer should be installed on each side of the flex hose fitting before installing
the banjo bolt. Tighten banjo bolt to a torque of 48 Nm (35 ft. lbs.).
7. Install the wheel and tire assembly.
8. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 135 Nm (100 ft. lbs.).
9. Lower vehicle.
CAUTION: After performing any service to the vehicle brake system, be sure to obtain a firm brake pedal before moving vehicle.
10. Remove the brake pedal holding tool.
11. Bleed the base brakes.
12. Road test the vehicle and make several stops to wear off any foreign material off the brakes and to seat the brake shoe linings.
