Five Hundred 2WD V6-3.0L VIN 1 (2006)
Disc Brake System - Exploded View
Removal
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the
brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink
water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with
water.
1. Check the brake fluid level in the brake master cylinder reservoir.
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If required, remove the fluid until the brake master cylinder reservoir is half full.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Using the large C-clamp, compress the pistons into the caliper housing.
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Position one end of the C-clamp on the outer pad between the caliper fingers, the other end on the caliper housing. During this process, the
outer brake pad will separate from the caliper housing.
4. Remove the brake pads.
5. Remove the brake caliper flow bolt and position the brake hose aside.
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Discard the copper washers.
6. Remove the brake caliper.
Installation
1. Clean the residual adhesive from the brake caliper-to-brake pad mating surfaces using brake parts cleaner.
2. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads.
NOTE: Install all new hardware as supplied with the brake pad kit.
Install the new spring clips and brake pads to the brake caliper anchor plate.
3. Position the brake hose and install the brake caliper flow bolt.
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Install new copper washers.
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Tighten to 30 Nm (22 ft. lbs.).
4. Bleed the brakes.
5. With the vehicles engine running, apply 89 - 133 N (20 - 30 lbs.) of pressure on the brake pedal for one minute to make sure the brake pads adhere
to the brake caliper.
6. With the vehicle engine running, apply 89 - 133 N (20 - 30 lbs.) of pressure on the brakes for approximately 1 minute, to make sure the brake
pads adhere to the caliper before any contamination can be introduced.
7. Test the brakes for normal operation.