Town & Country Van 2WD V6-201 3.3L VIN R MFI (1996)
Brake Caliper: Service and Repair
Disassembly and Assembly
Disassembly
1. Remove caliper from adapter and rotor. Do not disconnect brake hose from caliper. Support caliper at all times to prevent brake hose
damage.
2. Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place a small block of wood between caliper fingers to
prevent piston damage during removal.
3. Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any position below one inch of pedal travel to prevent
master cylinder brake fluid loss.
4. Disconnect brake hose at caliper, then mount caliper assembly in a soft jawed vise. Do not apply excessive vise pressure; caliper damage will
result.
5. Use a suitable screwdriver to remove dust boot, then use a plastic trim stick or other suitable non-metallic tool to pry piston seal out of piston bore
groove. Using a metallic tool for this operation may score piston bore.
6. Discard dust boot and piston seal; then, if necessary, remove caliper bushing and sleeve assembly as follows:
Removing Inner Sleeve From Bushing
a. Push inner sleeve out of bushing far enough to grasp sleeve end, then pull sleeve from bushing.
b. Gently collapse one side of bushing, then pull on opposite end to remove from caliper assembly.
Assembly
1. Clamp caliper in soft jawed vise. Do not apply excessive vise pressure; caliper damage will result.
2. Immerse new piston seal in clean brake fluid, then install in piston bore groove.
3. Coat new piston boot with clean brake fluid, then position boot over piston and install piston in caliper bore. Apply uniform force when pressing
piston into bore.
4. Position dust boot in caliper piston counterbore, then drive boot into counterbore using piston caliper boot installer tool No. C-4689 and handle
tool No. C-4171, or equivalents.
5. Install guide pin sleeve bushings as follows:
a. Fold bushing in half lengthwise at solid middle section, then carefully insert bushing into caliper assembly.
b. Using fingers or a suitable soft dowel, unfold bushing to seat in caliper assembly. Ensure flanges are seated evenly on both sides of bushing
hole.
6. Gently press guide pin sleeves through bushings until bushings seat in seal grooves, then ensure bushings and sleeves are installed properly by
sliding each back and forth. Sleeves should slide easily and bushings should remain seated in grooves.
7. Install caliper as outlined under Brake Pad/Service and Repair.
Inspection
1. Clean all caliper components in alcohol or other suitable solvent and wipe dry. Ensure bores and drilled passages are cleaned thoroughly.
2. Inspect piston bore for scoring or pitting. Crocus cloth may be used to remove minor scratches or corrosion.
3. If piston bore exhibits deep scratches or severe scoring, use caliper honing tool No. C-4095, or equivalent, to hone caliper bore. Do not increase
bore diameter more than 0.001 inch.
4. If caliper piston bore is to be honed, honing tool stones and piston bore should be coated with clean brake fluid, and honing should be followed by