1991-1996 Dodge Stealth Brake Caliper Problems and Replacement

By Core Brake Parts Tech Team — Circleville, OH warehouse

Most brake caliper problems on a 1991-1996 Dodge Stealth come down to age: a piston that has corroded in its bore and no longer retracts, a torn dust boot, or fluid that has not been changed in years. The fix is usually a replacement caliper (or a matched pair on the same axle), fresh fluid and new pads, and on these cars it is worth checking the front brake hoses at the same time because they were the subject of a factory recall.

How the Stealth Brake System Is Built

The Stealth is a Mitsubishi-built car, mechanically the same as the Mitsubishi 3000GT of the same years, so parts and service information are shared between the two. Every Stealth has four-wheel disc brakes, but the calipers differ a lot between the non-turbo cars and the all-wheel-drive R/T Turbo, and the Turbo changed again for 1994.

On the R/T Turbo, the front brakes use ventilated iron rotors with fixed (rigid) four-piston iron calipers in every model year. The rear is where the generations split: 1991-1993 Turbo cars have a single-piston floating rear caliper, while 1994 and later Turbo cars moved to a twin-piston fixed rear caliper along with larger rotors front and rear.

The non-turbo, front-wheel-drive Stealths (base, ES and the naturally aspirated R/T) use a different, lighter caliper and rotor package than the Turbo. Owner service write-ups based on the Turbo car specifically warn that the brakes are different on the non-turbo cars, so never assume a Turbo part fits a front-drive car or the other way around. Confirm trim, drivetrain and model year before ordering anything.

Common Caliper Problems and Their Symptoms

Thirty-year-old calipers fail in predictable ways. The symptoms tell you which one you are dealing with:

• Pull to one side. If the car drifts while cruising or pulls under braking, one caliper is either dragging or not applying fully.
• One hot wheel and a burning smell. After a drive, a wheel that is much hotter than the others points to a piston or pad that is not releasing. Check carefully; the rotor itself can burn you.
• Uneven pad wear. An inner pad worn far thinner than the outer on a floating caliper, or one pad in a fixed caliper worn more than its partner, means a piston is sticking.
• Soft or hard pedal. A leaking piston seal can give a soft pedal and wet residue on the inside of the wheel; a fully seized piston can make the pedal feel hard with little stopping power.
• Grinding or squealing that gets worse over time, often a dragging pad worn down to its backing plate.
• Lower fuel economy from constant brake drag you may not otherwise notice.

On the fixed four-piston front calipers of the Turbo, a single sticky piston will not always cause a dramatic pull, but it will show up as tapered or uneven pad wear. Pull the pads and look at both sides whenever you service the brakes.

Why Stealth Calipers Stick

Brake fluid absorbs moisture from the air. That water corrodes the piston and bore from the inside, and over time the piston can seize partially or fully extended so the pad stays against the rotor. Stealth enthusiast references note that fluid can pick up around 2 percent water on average within one to two years, which is why a car that has sat for long stretches is the most likely to have stuck calipers.

The second route is from the outside. When a dust boot tears, road water and salt get in behind it, rust the exposed piston and eventually damage the seal. Once the bore is pitted, new seals wear out quickly on the rough surface. A third cause is old, degraded fluid carrying sludge that slows piston movement.

Not every drag problem is the caliper. A brake hose that has collapsed internally can hold pressure on one wheel and mimic a stuck caliper. On the Stealth the front hoses deserve particular attention, covered next.

The Front Brake Hose Recall

Chrysler recall campaign 96V-143 covers the Stealth. Under full-lock steering combined with full suspension travel, the left or right front wheel-side brake hose can crack and leak brake fluid, which can light the brake warning lamp and reduce braking effectiveness. The remedy was replacement of both front wheel-side hoses with revised assemblies. NHTSA records list the campaign against the 1991 and 1993 model years among others; run your VIN through NHTSA or a dealer to see whether it was completed on your car.

Whether or not the recall was done, hoses on a car this age are due for inspection. Look for cracking, bulging when the pedal is pressed, and seepage at the fittings. If you are replacing a front caliper, it makes sense to replace the hoses at the same time from our brake hose selection, since the system is already open and needs bleeding anyway.

The Fix: Replace, Rebuild or Upgrade

Replace. For a daily driver, a new or remanufactured caliper is the most reliable repair. Brake manufacturers point out that rebuilding with only a seal kit often fails because any remaining corrosion or pitting in the bore quickly damages the new seals. Replace calipers in pairs on the same axle so braking force stays balanced. Browse our brake calipers and confirm the listing matches your trim and year.

Rebuild. Rebuild kits make sense only when the bore and piston are clean and smooth. If you see pitting or rust on the piston face or bore walls, replace the caliper.

Upgrade (Turbo cars). Many 1991-1993 R/T Turbo owners install the 1994-and-later Turbo caliper set, which bolts onto the early cars. The later calipers go with the larger rotors, so new rotors and pads are required as part of that swap.

Service tips during the job:

• Open the brake fluid reservoir cap before pushing pistons back, and press with steady, even pressure across the piston face so you do not cock or dent it.
• On the Turbo front calipers, the two mounting bolts are very tight from the factory. Use a long breaker bar to remove them, and torque them back to the value in the factory service manual, not a guess.
• When fitting new pads, a small amount of silicone brake grease on the piston tip and inside the boot lip helps keep moisture out and the piston moving freely.
• Flush the fluid with fresh DOT 3 or DOT 4, which is what Mitsubishi specifies for these cars, and bleed every corner.

What to Replace at the Same Time

A seized caliper overheats and chews its pads, so plan on new pads for that axle at minimum. Check the rotors for heat spots, scoring and thickness against the minimum stamped on the rotor or listed in the service manual, and replace them from our brake rotor collection if they are marginal.

Pads we carry for this car include the EBC Redstuff front pads for the 1991-1996 Stealth 3.0 2WD, the EBC Redstuff ceramic front pads for the 1991-1993 Stealth AWD, the more aggressive EBC Yellowstuff street and track front pads for 1991-1993 AWD, and the EBC Greenstuff rear pads for the 1994-1996 Stealth AWD. Notice how the fitment splits by drivetrain and by generation, just like the calipers. New brake hardware is also worth fitting when the old clips are rusted.

As for difficulty, a caliper swap is a reasonable home job for someone who has done pads before; the main challenges are stubborn bolts and a thorough bleed afterward. If the car has ABS, follow the bleeding procedure in the service manual, and if the pedal is still soft after bleeding, have a shop check it.

Frequently Asked Questions

Do all Dodge Stealth models use the same calipers?

No. The AWD R/T Turbo uses fixed four-piston front calipers, and its rear caliper changed from single-piston floating (1991-1993) to twin-piston fixed (1994-1996). The front-drive non-turbo cars use a different brake package altogether. Always match trim, drivetrain and year.

Can I put 1994-1996 Turbo calipers on a 1991-1993 Stealth R/T Turbo?

Yes, the later Turbo caliper set bolts onto the early Turbo cars, but you need the matching larger rotors and pads to complete the swap.

Should I replace one caliper or both?

Replace them in pairs on the same axle. A new caliper on one side and a tired one on the other can cause a pull and uneven pad wear.

What brake fluid does a Dodge Stealth use?

Mitsubishi specifies DOT 3 or DOT 4 for all years. Flush it on a regular schedule, since moisture in old fluid is the main reason these calipers seize.

Why does my Stealth pull to one side when braking?

The most common causes are a sticking caliper piston, a collapsed or damaged front brake hose, or contaminated pads on one side. Check for a hot wheel and uneven pad wear, and inspect the front hoses, which were the subject of recall 96V-143.

Sources

1. Stealth 316 - Brake Upgrade Options - caliper types, piston counts, rotor sizes by year, DOT 3/DOT 4 fluid, moisture absorption, piston grease tip
2. Stealth 316 - Brake Rotor and Pad Replacement - Turbo caliper removal, piston retraction, non-turbo brakes differ
3. 3S Warehouse - 2G Turbo Brake Caliper Set - 1994+ Turbo calipers bolt onto 1991-1993 cars with new rotors and pads
4. Center for Auto Safety - 1993 Dodge Stealth - recall 96V-143 front brake hose defect and remedy
5. NHTSA Recalls - 1991 Dodge Stealth - recall 96V-143 listed for the 1991 model year
6. NRS Brakes - Sticky or Seized Caliper Pistons - symptoms, causes, replace versus rebuild