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Chrysler 200 Front Brake Pads Replacement Guide
How to change the front disc brake pads on a 2nd generation 2015, 2016 or 2017 Chrysler 200 with the part numbers.

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2015 Chrysler 200 Front Wheel
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Slightly Loosen Lug Bolts
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Raise Front of Car

This automotive maintenance tutorial was specifically written to assist owners of the second generation 2015, 2016 and 2017 Chrysler 200 sedan in changing the front disc brake pads and lubricating the caliper slider pins.

Owners of other Chrysler, Dodge, Jeep, RAM or Fiat vehicles such as the 300, Pacifica, Town & Country, Avenger, Charger, Challenger, Journey, Dart, Durango, Magnum, Grand Caravan, Fiat 500, Fiat 124 Spider, Grand Cherokee, Renegade, Wrangler, Compass, Liberty, Patriot, ProMaster, 1500 and C/V Tradesman minivan may also find these DIY instructions to be helpful.

A few compatible replacement sets of new front brake pads with their part numbers are as follows: ACDelco 17D1623ACH, Bosch BC1640, Power Stop (16-1640) Z16, ADVICS AD1640, and ProStop PGD1640C.

The tools and other items needed to complete this procedure include a lug nut wrench, a floor jack, two jack stands, a 14mm socket, a 3/8" drive ratchet, an "F" clamp and a tube of brake caliper grease.

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Spin Off 5 Lug Bolts
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Five Lug Bolts Removed
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Remove Front Wheel
The first few steps are to park the car on a level surface, turn off the ignition and shift the transmission in to "Park".

Then engage the emergency / parking brake and place wheel chocks on both sides of the rear tires to prevent the vehicle from moving.

Slightly loosen the five bolts on the front wheel with the lug nut wrench by turning them about 1/4 to 1/2 turn in the counterclockwise direction.

Raise the front of the car with the floor jack and securely support it with at least two jack stands.

I prefer to work on one side of the car to keep three tires on the ground for extra safety.

Spin off the five lug bolts and set them aside in a safe place.

Carefully remove the front wheel to reveal the front brake rotor, bracket, caliper and suspension.

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Front Brake Caliper
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Loosen Top Caliper Bolt
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Loosen Bottom Caliper Bolt
The front brake caliper is held in place to the bracket by two bolts located on the back side of the caliper with the bolt heads facing in towards the engine bay.

Loosen the top caliper bolt by turning it clockwise (as seen from the outside of the car) with the 14mm socket and a 3/8" drive ratchet.

Then loosen the bottom 14mm caliper bolt by turning it clockwise (as seen from the outside of the vehicle).

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Spin Out Upper Bolt
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Spin Out Lower Bolt
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Pull Off Front Brake Caliper
Spin out the two caliper bolts and set them aside in a safe place.

Carefully pull the caliper out of the bracket and off the old brake pads.

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Rest Caliper On Suspension
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Pull Off Old Outer Pad
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Wear Bar - Top Inner Pad
Rest the caliper on the suspension or suspend it from the spring with a bungee cord.

Pull the old inner and outer brake pads out of the caliper bracket.

Make a mental note of where the wear indicator or "squeal" bar is situated on the old brake pads.

On this 2015 Chrysler 200, the wear indicator bar was located at the top of the inner brake pad.

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Replace Pad Abutment Clips
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Lubricate Caliper Slider Pins
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Install New Outer Pad
If your new set of front brake pads includes replacement brake hardware, pull the old metal pad abutment or "anti-rattle" clips out of the top and bottom of the bracket.

Apply a thin layer of brake caliper grease to the part of the new pad abutment clips where they will come in contact with the bracket or the new brake pads.

Push the new pad abutment clips in to the top and bottom of the bracket.

In order for the caliper to operate smoothly, the two caliper slider pins or "guide bolts" need to be well lubricated.

Pull the  caliper slider pins out of their rubber dust boots attached to the caliper bracket.

Apply a thin layer of brake parts lubricant grease to the smooth parts of the two caliper slider pins before pushing them back in to place.

Thoroughly clean off the brake rotor, caliper bracket, lug bolt holes and the brake caliper assembly with brake parts cleaner spray. Do not use compressed air or blow with your mouth to clean off the brake parts since inhaling brake dust can be harmful to your health. Brake dust can be carcinogenic (cancer causing) if inhaled.

If your 200 sedan previously exhibited shuddering, pulsating, or vibrations in the front end during braking, you might need to have your rotors "turned" (resurfaced) or just replace them with brand new rotors. If this is the car's first front brake job and the rotors appear to be in excellent condition, you should be able to just change the pads with excellent results.

To remove the existing rotors and install new ones, remove the set screw on the front of the rotor (should be a Torx T-30 screw), remove the two bolts on the rear of the caliper bracket that attach it to the steering knuckle. Remove the bracket and set it aside in a safe place. Then loosen the old rotor with a rubber mallet, pull it off, and slide the new one in its place.



 

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Install New Inner Pad
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Push Pads Against Rotor
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Attach "F" Clamp To Caliper
Install the two new brake pads in to the bracket with the wear indicator bar situated at the top of the new inner brake pad.

Push the two pads together until they are flush against the rotor.

In order for the caliper to fit over the thicker new brake pads, you'll need to compress back the caliper piston.

Attach the "F" clamp to the caliper and use the back of an old brake to evenly distribute the pressure across the piston.

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Brake Fluid Reservoir
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Twist Off Counterclockwise
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Compress Caliper Piston
Move to the right rear area of the engine bay and twist off the yellow plastic cap on the brake fluid reservoir in the counterclockwise direction.

Removing the reservoir cap will allow the brake fluid to more easily travel back through the lines when you compress the caliper piston.

Rotate the "F" clamp handle in the clockwise direction to retract back the caliper piston until it is almost flush with the rubber dust boot surrounding it.

Try to avoid pinching or otherwise damaging the rubber dust boot that surrounds the caliper piston.

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Replace Brake Fluid Cap
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Replace Brake Caliper
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Spin In Top Caliper Bolt
Replace the brake fluid reservoir cap as soon as possible by twisting it on in the clockwise direction.

Brake fluid is "hygroscopic" which means that it easily absorbs moisture from the air which can lead to reduced braking performance.

Lower the brake caliper over the new brake pads and in to the bracket.

Line up the bolt holes in the caliper with their corresponding bolt holes in the caliper slider pins within the bracket.

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Spin In Bottom Caliper Bolt
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Tighten Lower Caliper Bolt
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Tighten Upper Caliper Bolt
Spin in the two caliper bolts a few turns by hand in the counterclockwise direction to prevent them from becoming cross threaded.

Tighten the two caliper bolts in the counterclockwise direction (as seen from the outside of the car) with the 14mm socket and a 3/8" drive ratchet to just past hand tight or about 32 lb-ft of torque.

Double check that the two caliper bolts are tight before moving on to the next steps.

If your brake pedal has been feeling soft or spongy, the brake fluid might be contaminated with water or the brake lines may contain a some air bubbles.

It would be best to bleed the brake lines at this time in order to flush out the old fluid and replace it with new DOT 3 brake fluid. For more on this topic, check out my Brake Line Fluid Bleeding With An Assistant DIY Guide or alternatively the Brake Line Fluid Bleeding With A Power Bleeder Guide.

The brake fluid bleeder valve is covered by a rubber cap and located just below the top caliper bolt.

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Replace Front Wheel
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Spin In 5 Lug Bolts
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Slightly Tighten Clockwise
Replace the front wheel and spin in the five lug bolts in the clockwise direction a few turns by hand to prevent it from becoming cross threaded.

Slightly tighten the five lug bolts in a criss cross or star pattern with the tire iron.

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Lower Car From Stands
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Torque To 100 lb-ft
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Front Brake Pads Replaced
Carefully lower the car from the jack stands by using the floor jack.

Continue tightening the lug bolts in the clockwise direction with the lug nut wrench to about 1/4 turn past hand tight or about 100 lb-ft of torque.

It would be best to use a torque wrench or an electric impact wrench with a 100 lb-ft torque stick to properly tighten the lug bolts.

Sit in the driver's seat of the car and firmly push down the brake pedal a few times to restore the brake line pressure. Check the brake fluid in the reservoir and verify that it is at the proper level. If it is low, add some fresh DOT 3 fluid.

To break in your new front brake pads, just drive normally for the first several hundred miles while trying to avoid any hard or "panic" stops which might glaze over the new pads and cause them to be noisy and/or not perform as well.

It's also a good idea to regularly check your driveway for drops of fresh brake fluid which may indicate a leak, check the brake fluid level in the reservoir, and also verify that the lug bolts are still tight.

Be sure to record the brake pad change in your car's service records.

For more, please check out all of my 2015-2017 Chrysler 200 DIY Repair & Maintenance Guides.
 

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