How to Replace a Caliper in a Dodge Intrepid
The Dodge Intrepid is a discontinued model, so finding replacement parts and service may grow difficult. Before replacing an important part, like a brake caliper, on an Intrepid, consult with your mechanic to get the exact parts needed.
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Things You'll Need
- Allen wrench
- Tire iron
- Jack
- Oil/fluid pan
- Caliper for Intrepid
- Copper washers
- Small rubber piece
Instructions
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Removal
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1
Disconnect the wheel and tire from the car once it's securely raised. Remember to disconnect the lug nuts in a five-star pattern, removing each one opposite from the one previously removed.
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2
Remove the two caliper guide pin bolts and the caliper assembly. Disconnect the brake hose from the caliper by removing the retaining bolt. Plug the hole to avoid contamination.
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3
Pivot the caliper upwards from the rotor. Slide it off of the pin boot.
Preparing the New Caliper
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4
Connect the brake hose to the new caliper. Use new washers when attaching the bolt.
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5
Push the caliper pistons into their bore. This is needed if you installed new linings to accommodate their thickness. A large C-clamp should do the job.
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6
Install the brake pads into the caliper. Lubricate the machined areas that support the caliper, using a high-temperature grease.
Installation
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7
Attach the caliper to the steering knuckle in its proper position. Install the guide pin bolts, making sure you don't cross their threads.
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8
Torque the guide pin bolts to 15 foot pounds. Torque the brake hose fittings to 35 foot pounds.
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9
Bleed the brake system to remove air from it. The best way would be to attach a transparent hose to the opened bleeder valve and hold down on the brake pedal. (This will require two people.)
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10
Reattach the wheel and tire, and then lower the car.
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11
Seat the brake pads against the rotors by pumping the pedal. Check the fluid level and add as much as needed. Road test the car and brakes.
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1
Tips & Warnings
Remove a third to half of the brake fluid before beginning. This can prevent brake fluid being forced through the lines as you install the caliper, causing overflow.
Never clean brake parts while dry, as they can contain asbestos. Run a fine mist of water over the parts, wipe with a damp rag and dispose of the rag in an airtight container.
