Q: How to Service and Repair a Brake Caliper on 2006 Chrysler PT Cruiser?
A: Before servicing the brake caliper, use a brake pedal holding tool to push the brake pedal beyond its initial inch of movement. Hold up and secure the car, take out the wheel mounting nuts and then remove the tire and wheel assembly. To disconnect the brake hose, remove the banjo bolt and get rid of the washers. After that, take off both brake guide pin bolts and take the brake caliper off the adapter and braking pads. Before you start to disassemble, wash and check the caliper (including pistons) and remember that air pressure can hurt you if you spray it directly on the piston. Put the caliper in a vise, using protective jaws, set a wooden block in it and if there is a fluid inlet, blow a light pressure of compressed air through it to push out the piston. Unscrew the piston and bin the dust boot. Pull out the piston seal with a soft extractor, wipe down the inside of the piston bore using alcohol or a gentle solvent and have a look for any damage. Before wiping dry, use water to dampen the brake parts and then clean them carefully with a damp towel, being sure to dispose of any pieces containing asbestos safely. Assemble the brake by cleaning your hands, using new brake fluid, dipping the new seal in brake fluid, then fitting it inside the caliper bore groove. Add fluid to the piston and its boot, hold both parts in place, insert the piston into the bore so it sits right and then carefully press the piston inside. Attach the caliper, use a C-clamp to withdraw the piston and set the caliper properly above the brake pads. Fit the two guide pin bolt holes together, put in the guide pin bolts and tighten them to 35 Nm. Put a new banjo bolt and washers on the brake hose and tighten them onto the brake caliper using 24 Nm of force. Fit the tire and wheel assembly back onto the hub, tighten the wheel mounting nuts to the required 135 Nm, lower the vehicle, take off the caliper bleed tool, release any air bubbles as necessary and make sure the brakes are working properly during a road trial.