Chrysler PT Cruiser, Service & Repair Manual, Page: 127 / 2078

INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors.
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers.
Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point.
•
For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.
•
For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 9.0
mm (3/8 inch), they should be replaced.
•
Typically, if front shoes are worn out, both fronts
and rears need to be replaced. Make sure to check
rears.
Replace both disc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were remove from.
INSTALLATION
CAUTION: When installing new brake components,
be sure to use correct parts. Parts designed for
BR4 Performance Brake System must not be mixed
with other brake systems. These parts, similar in
appearance, can be easily identified (Fig. 14) (Fig.
15).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL
- DESCRIPTION - DISC BRAKES (REAR))
NOTE: Perform Step 1 through Step 7 on each side
of the vehicle to complete shoe set installation,
then proceed to Step 8.
(1) Completely retract the caliper piston back into
piston bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.
(2) Install the inboard brake shoe into the caliper
piston by firmly pressing the shoe in with the
thumbs (Fig. 24). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(3) Slide the outboard brake shoe onto the caliper
assembly (Fig. 23). Be sure the retaining clip is
squarely seated in the depressed areas on the caliper.
(4) Lubricate both adapter caliper slide abutments
with a liberal amount of Mopar
t
Multipurpose Lubri-
cant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(5) Starting with the lower end, carefully lower the
caliper and brake shoes over the brake rotor and
catch the caliper’s bottom edge behind the caliper
slide abutment (Fig. 21). Rotate the top of the caliper
into mounting position on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(6) Carefully install the caliper guide pin bolts
(Fig. 20), then tighten them to a torque of 22 N·m
(192 in. lbs.).
(7) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(8) Lower the vehicle.
(9) Pump the brake pedal several times to ensure
the vehicle has a firm brake pedal before moving the
vehicle.
(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE PADS/SHOES - REAR
DRUM
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove both rear tire and wheel assemblies
from vehicle.
NOTE: Perform Step 3 through Step 11 on each side
of the vehicle to complete shoe set removal. It may
be easier to install the new components on the first
side of the vehicle before disassembling the oppo-
site side, so it may be used as a reference guide for
proper installation. (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/BRAKE
PADS/SHOES - REAR
DRUM - INSTALLATION)
PT
BRAKES - BASE 5 - 19
BRAKE PADS/SHOES - REAR DISC (Continued)