Caravan AWD V6-201 3.3L (1991)
Brake Caliper: Service and Repair
Disassembly and Assembly
Cleaning, Inspecting & Honing Caliper
Honing Brake Caliper Piston Bore
Inspect the piston bore for scoring or pitting
-
Bores that show light scratches or corrosion, can usually be cleared with crocus cloth.
-
Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the diameter of the bore is not increased more than
0.0254 mm (0.001 inch).
-
If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or
scored.
When using a hone:
Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean,
lintless cloth and then clean a second time.
Be sure to install the hone baffle before honing bore.
-
The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing.
Kelsey-Hayes Double Pin Caliper
DISASSEMBLING CALIPER
1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss.
2. Place a small piece of wood between the piston and caliper fingers.
3. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening).
4. Prop brake pedal to any position below the first inch of pedal travel -- to prevent loss of brake fluid.
If both front caliper pistons are to be removed:
1. Disconnect flexible brake line at frame bracket after removing piston.
2. Plug brake tube and remove piston from opposite caliper.
WARNING: Under no condition should air pressure be used to remove piston from bore! Personal Injury could result from such
practice.
3. Disconnect brake flexible hose from the caliper.
4. To disassemble, mount caliper assembly in a vise equipped with protective jaws.
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
