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BR/BE

BRAKES

5 - 1

BRAKES

TABLE OF CONTENTS

 

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BRAKES - BASE

 

INSTALLATION

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20

SPECIFICATIONS

 

2

ROTORS

SPECIAL TOOLS

4

DIAGNOSIS AND TESTING

20

HYDRAULIC/MECHANICAL

 

DISC BRAKE ROTOR

20

DESCRIPTION

 

4

REMOVAL

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21

WARNING DIAGNOSIS AND TESTING

5

5

INSTALLATION

. BRAKE PADS/SHOES

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22

BASE BRAKE SYSTEM

5

REMOVAL

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23

STANDARD PROCEDURE

7

INSTALLATION

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26

MANUAL BLEEDING

7

. MASTER CYLINDER

PRESSURE BLEEDING

 

8

DESCRIPTION

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29

BRAKE LINES STANDARD PROCEDURE

8

. DIAGNOSIS AND TESTING

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OPERATION

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. 29

29

DOUBLE INVERTED FLARING

8

MASTER CYLINDER/POWER BOOSTER

 

29

ISO FLARING

8

STANDARD PROCEDURE

30

COMBINATION VALVE

 

MASTER CYLINDER BLEEDING

 

30

DESCRIPTION

 

9

REMOVAL

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30

OPERATION

9

INSTALLATION

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30

DIAGNOSIS AND TESTING

9

. WHEEL CYLINDERS

COMBINATION VALVE

9

REMOVAL

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REMOVAL

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10

DISASSEMBLY

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31

INSTALLATION

 

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10

CLEANING

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31

DISC BRAKE CALIPERS

 

INSPECTION

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31

REMOVAL

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ASSEMBLY

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DISASSEMBLY

 

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. 11

INSTALLATION

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32

CLEANING

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12

SUPPORT PLATE

INSPECTION

 

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REMOVAL

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32

ASSEMBLY

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. 12

INSTALLATION

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32

INSTALLATION

 

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13

DRUM

FLUID

DESCRIPTION

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32

DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION STANDARD PROCEDURE

 

14

14

14

. DIAGNOSIS AND TESTING

OPERATION

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BRAKE DRUM

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33

33

BRAKE FLUID LEVEL

14

. STANDARD PROCEDURE

33

SPECIFICATIONS FLUID RESERVOIR

 

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15

BRAKE DRUM MACHINING

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33

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REMOVAL

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15

CLEANING INSPECTION

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33

INSTALLATION

 

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15

ADJUSTMENTS

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34

PEDAL

PARKING BRAKE

DESCRIPTION

 

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16

DESCRIPTION

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35

OPERATION

 

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. 16

OPERATION

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. 36

REMOVAL

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16

PEDAL

INSTALLATION

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POWER BRAKE BOOSTER

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17

REMOVAL INSTALLATION

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36

36

DIAGNOSIS AND TESTING HYDRAULIC BOOSTER STANDARD PROCEDURE

 

17

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19

CABLES REMOVAL INSTALLATION

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37

38

POWER BRAKE BOOSTER

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19

. CABLE TENSIONER

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REMOVAL

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19

ADJUSTMENTS

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40

5 - 2

BRAKES

BR/BE

RELEASE

SHOES

REMOVAL

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40

REMOVAL

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41

INSTALLATION

 

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INSTALLATION

 

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42

BRAKES - BASE

SPECIFICATIONS BASE BRAKE

SPECIFICATIONS

 

DESCRIPTION

SPECIFICATION

Front/Rear Disc Brake Caliper Type

Dual Piston Sliding

Front Disc Brake Caliper Piston Diameter LD

54

mm (2.00 in.)

Front Disc Brake Caliper Piston Diameter HD

56

mm (2.00 in.)

Front Disc Brake Rotor

304× 30 mm (11.96× 1.18

1500

4x2

in.)

Front Disc Brake Rotor

307.5 ×30 mm

1500

4x4

(12.10× 1.18 in.)

Front Disc Brake Rotor

326.5 ×36 mm (12.5 × 1.5 in.)

2500/3500

Front/Rear Disc Brake Rotor Max. Runout

0.127

mm (0.005 in.)

Front/Rear Disc Brake Rotor Max. Thickness Variation

0.025

mm (0.001 in.)

Mininium Front Rotor Thickness

28.39

mm (1.117 in.)

1500

 

Minimum Front Rotor Thickness

33.90

mm (1.334 in.)

2500/3500

 

Mininium Rear Rotor Thickness

28.39

mm (1.117 in.)

2500/3500

 

DESCRIPTION

SPECIFICATION

Drum Brake

279× 57 mm (11× 2.25 in.)

Size

1500

Drum Brake

308× 89 mm (12.125× 3.5 in.)

Size

2500/3500

 

Drum Brake

0.18

mm (0.007 in.)

Max. Runout

 

1500

Drum Brake

0.076 mm (0.003 in.)

Max. Thickness Variation

1500

Rear Disc Brake Caliper

2x45 mm (1.77 in)

2500

Rear Disc Brake Caliper

2x51 mm (2.00 in)

3500

Rear Disc Brake Rotor

323.5x30 mm (1.18 in)

2500/3500

Wheel Cylinder Bore Size

25.4

mm (1.00 in.)

1500

 

Wheel Cylinder Bore Size

25.4

mm (1.00 in.)

2500/3500

 

Brake Booster Type 1500/2500 Gasoline Engines

Vacuum Dual Diaphragm

Brake Booster Type All 3500/ 2500 Diesel Engines Only

Hydraulic

BR/BE

BRAKES

5 - 3

BRAKES - BASE (Continued)

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Booster

28

21

250

Mounting Nuts

Booster Mounting Nuts to the Dashpanel

33

24

300

Diesel Hydraulic Booster Mounting Bolts

28

21

250

Diesel Hydraulic Booster Booster Lines

28

21

250

Diesel Hydraulic Booster Booster Hoses

31

23

275

Master Cylinder

23

17

200

Mounting Nuts

Master Cylinder

21

16

190

Brake Lines

Combination Valve Mounting Bolt

23

17

210

Combination Valve Brake Lines

21

16

190

Proportioning Valve Mounting Nuts

34

25

300

Proportioning Valve Brake Hose

31

23

276

Proportioning Valve Brake Lines

21

16

190

Front Caliper

33

24

Mounting Bolts

Front Caliper LD Adapter Bolts

176

130

Front Caliper HD Adapter Bolts

285

210

Rear Caliper

33

24

300

Slide Pins

Rotor to Hub Rear Bolt

128

95

All Caliper

40

30

360

Banjo Bolts

Wheel Cylinder

20

15

180

Mounting Bolts

Wheel Cylinder

13

10

115

Brake Line

Support Plate

58

43

Mounting Bolts

5 - 4

BRAKES

BR/BE

BRAKES - BASE (Continued)

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Park Brake Pedal Assembly Mounting Bolts/Nuts

28

21

250

Hub/Bearing LD 4x2 Spindle Nut

251

185

Hub/Bearing HD 4x2 Spindle Nut

380

280

Hub/Bearing 4x4 Hub/Bearing Bolts

170

125

SPECIAL TOOLS BASE BRAKES

Bolts 170 125 — SPECIAL TOOLS BASE BRAKES Installer, Brake Caliper Dust Boot C-4340 Installer, Brake

Installer, Brake Caliper Dust Boot C-4340

TOOLS BASE BRAKES Installer, Brake Caliper Dust Boot C-4340 Installer, Brake Caliper Dust Boot C-3716-A Handle

Installer, Brake Caliper Dust Boot C-3716-A

Dust Boot C-4340 Installer, Brake Caliper Dust Boot C-3716-A Handle C-4171 Cap, Master Cylinder Pressure Bleed

Handle C-4171

Installer, Brake Caliper Dust Boot C-3716-A Handle C-4171 Cap, Master Cylinder Pressure Bleed 6921

Cap, Master Cylinder Pressure Bleed 6921

HYDRAULIC/MECHANICAL

DESCRIPTION

This vehicle is equipped wit h fr ont disc br a kes a n d

r ea r dr um br a kes also cert ain

wh eel disc br a kes.

con sist of du al pist on caliper s a n d ventilat ed r ot or s.

Th e r ea r br a kes a r e du al br a ke sh oe, int er n al

vehicles h a ve fou r

br a kes

Th e fr ont a n d r ea r disc

expa n din g u nit s wit h

ca st

br a ke dr um s. Th e pa r kin g

br a ke m ech a nism is

ca ble

oper at ed a n d con n ect ed t o

t h e

st a n da r d equipm ent. A va cu um oper at ed power br a ke

r ea r br a ke t r ailin g sh oes. P ower br a ke a ssist is

boost er

is u sed on ga s en gin e

vehicles. A h ydr a ulic

boost er

is u sed on diesel en gin e

vehicles.

Two a ntilock br a ke syst em s a r e u sed on t his vehi-

cle. A r ea r wh eel a ntilock (RWAL) br a ke syst em a n d all-wh eel a ntilock br a ke syst em (ABS). Th e RWAL

a n d ABS syst em s a r e design ed t o r et a r d wh eel

locku p while br a kin g. Ret a r din g wh eel locku p is

m odulatin g fluid pr essu r e t o t h e

wh eel br a ke u nit s. Bot h syst em s a r e m onit or ed by a micr opr ocessor which cont r ols t h e oper ation of t h e systems.

a ccom plish ed by

BR/BE

BRAKES

5 - 5

HYDRAULIC/MECHANICAL (Continued)

WARNING

WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON- TAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. USE A VACUUM CLEANER SPE- CIFICALLY DESIGNED FOR THE REMOVAL OF ASBESTOS FIBERS FROM BRAKE COMPONENTS. IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- ABLE, CLEANING SHOULD BE DONE WITH A WATER DAMPENED CLOTH. DO NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DISPOSE OF ALL RESIDUE CONTAINING ASBES- TOS FIBERS IN SEALED BAGS OR CONTAINERS TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- ERS. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINIS- TRATION AND THE ENVIRONMENTAL PROTECTION AGENCY FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS.

CAUTION: Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing mineral oil to clean the system components. These fluids damage rubber cups and seals. Use only fresh brake fluid or Mopar brake cleaner to clean or flush brake system components. These are the only cleaning materials recommended. If system contam- ination is suspected, check the fluid for dirt, discol- oration, or separation into distinct layers. Also check the reservoir cap seal for distortion. Drain and flush the system with new brake fluid if con- tamination is suspected.

DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM

Ba se br a ke com pon ent s con sist of t h e br a ke sh oes, caliper s, wh eel cylin der s, br a ke dr um s, r ot or s, br a ke lin es, m a st er cylin der, boost er, a n d pa r kin g br a ke com pon ent s. Br a ke dia gn osis in volves det erminin g if t h e pr ob-

lem is r elat ed t o a m ech a nical, h ydr a ulic, or oper at ed com pon ent. Th e fir st dia gn osis st ep is t h e pr elimin a r y ch eck.

va cu um

PRELIMINARY BRAKE CHECK

(1) Ch eck con dition of tir es a n d wh eels. Dam a ged

wh eels a n d wor n, dam a ged, or u n derin flat ed tir es

sh u dder, vibr ation, a n d a con dition

similar to grab.

wh en br a kin g, fr ont a n d r ea r

ch eck su spen sion com pon ent s. J ou n ce

of vehicle a n d list en for n oise t h at might be ca u sed by loose, wor n or dam a ged su spen sion or st eerin g com pon ent s. (3) In spect br a ke fluid level a n d con dition. Not e

t h at t h e br a ke r eser voir fluid level will decr ea se in

pr oportion t o n orm al linin g wea r. Also note that

brake fluid tends to darken over time. This is normal and should not be mistaken for contam- ination. (a ) If fluid level is a bn orm ally low, look for evi-

den ce of lea ks at caliper s, wh eel cylin der s, br a ke lin es, a n d m a st er cylin der.

out a

ca n ca u se pull,

(2) If com plaint wa s ba sed on n oise

(b) If fluid a ppea r s cont amin at ed, dr ain

sam ple

t o examin e. Syst em will

h a ve t o be flu sh ed

if fluid

is sepa r at ed int o la yer s,

or cont ain s a su b-

st a n ce ot h er t h a n br a ke fluid.

Th e syst em seals

a n d cu ps will also h a ve t o be r epla ced a ft er flu sh - in g. Use clea n br a ke fluid t o flu sh t h e syst em.

(4) Ch eck pa r kin g br a ke oper ation. Verify fr ee

m ovem ent a n d full r elea se of ca bles a n d pedal. Also

n ot e if vehicle wa s bein g oper at ed wit h pa r kin g brake partially applied.

 

(5) Ch eck br a ke pedal oper ation.

Verify t h at

pedal

 

does n ot bin d a n d h a s a dequ at e fr ee pla y. If

pedal

CAUTION: Use Mopar brake fluid, or an equivalent

la

cks fr ee pla y, ch eck pedal a n d power boost er for

quality fluid meeting SAE/DOT standards J1703 and

bein g loose or

for bin d con dition.

Do n ot

r oa d t est

DOT 3. Brake fluid must be clean and free of con-

u

ntil

con dition

is cor r ect ed.

taminants. Use fresh fluid from sealed containers

(6)

Ch eck boost er va cu um ch eck

valve a n d h ose.

only to ensure proper antilock component opera-

(7)

If com pon ent s ch ecked a ppea r OK, r oa d t est

tion.

t

h e vehicle.

 

CAUTION: Use Mopar multi-mileage or high temper- ature grease to lubricate caliper slide surfaces, drum brake pivot pins, and shoe contact points on the backing plates. Use multi-mileage grease or GE 661 or Dow 111 silicone grease on caliper slide pins to ensure proper operation.

ROAD TESTING

(1) If com plaint in volved low br a ke pedal, pum p pedal a n d n ot e if it com es ba ck u p t o n orm al h eight. (2) Ch eck br a ke pedal r espon se wit h t r a n smission in Neut r al a n d en gin e r u n nin g. P edal sh ould r em ain firm u n der con st a nt foot pr essu r e.

5 - 6

BRAKES

BR/BE

HYDRAULIC/MECHANICAL (Continued)

(3) Du rin g r oa d t est, m a ke n orm al a n d firm br a ke

st ops in 25-40 m ph r a n ge. Not e fa ult y br a ke oper a -

pedal pulsa -

tion, pull, gr a b, dr a g, n oise, et c. (4) Att em pt t o st op t h e vehicle wit h t h e pa r kin g br a ke only a n d n ot e gr a b, dr a g, n oise, et c.

tion su ch a s low pedal, h a r d pedal, fa de,

PEDAL FALLS AWAY

A br a ke pedal t h at falls awa y u n der st ea dy foot

pr essu r e is gen er ally t h e r esult of a syst em lea k. Th e lea k point could be at a br a ke lin e, fittin g, h ose, or

caliper/wh eel cylin der. If be evident at or a r ou n d

by-pa ss) in t h e m a st er cylin -

der ca u sed by wor n or dam a ged pist on cu ps, m a y

also be t h e pr oblem ca u se.

lea ka ge is sever e, fluid will t h e lea kin g com pon ent.

Int er n al lea ka ge (seal

An int er n al lea k in t h e ABS or RWAL syst em m a y also be t h e pr oblem wit h n o ph ysical eviden ce.

LOW PEDAL

 

If

a low pedal is experien ced, pum p t h e pedal sev-

er al

tim es. If t h e pedal com es

ba ck u p, wor n linin gs,

r

ot or s, dr um s, or r ea r br a kes

out of a dju stm ent a r e

t

h e m ost likely ca u ses. Th e pr oper cou r se of a ction is

t

o in spect a n d r epla ce all wor n com pon ent

a n d m a ke

t

h e pr oper a dju stm ent s.

SPONGY PEDAL

 

A

spon gy pedal is m ost oft en ca u sed by

air in t h e

syst em. H owever, t hin br a ke dr um s or su bst a n da r d

br a ke lin es a n d

Th e pr oper cou r se of

a n d r epla ce t hin dr um s a n d su bst a n da r d qu alit y br a ke h oses if su spect ed.

is t o bleed t h e syst em,

h oses ca n also ca u se a spon gy pedal.

a ction

HARD PEDAL OR HIGH PEDAL EFFORT

be du e t o

linin g t h at is wat er soa ked, cont amin at ed, gla zed, ba dly wor n. Th e power boost er or ch eck valve could also be fa ult y.

or

A h a r d pedal or high pedal effort m a y

PEDAL PULSATION

P edal pulsation is ca u sed by com pon ent s t h at a r e loose, or beyon d t oler a n ce limit s.

Th e prim a r y ca u se of pulsation a r e disc br a ke

r u n out or t hickn ess va ri- dr um s. Ot h er ca u ses a r e

loose wh eel bea rin gs or caliper s a n d wor n or dam - aged tires.

ation, or out of r ou n d br a ke

r ot or s wit h excessive lat er al

NOTE: Some pedal pulsation may be felt during ABS/EBD activation.

BRAKE DRAG

Br a ke dr a g occu r s wh en t h e linin g is in con st a nt cont a ct wit h t h e r ot or or dr um. Dr a g ca n occu r at on e wh eel, all wh eels, fr ont s only, or r ea r s only.

sh oe r elea se. over h eat t h e

Dr a g ca n be min or or sever e en ou gh t o

linin gs, r ot or s a n d dr um s. Min or dr a g will u su ally ca u se slight su r fa ce ch a r -

rin g of t h e

linin g. It ca n also gen er at e h a r d spot s in

r ot or s a n d dr um s fr om t h e over h eat -cool down pr o-

cess. In m ost ca ses, t h e

r ot or s, dr um s, wh eels a n d

tir es a r e quit e wa rm t o t h e t ou ch a ft er t h e vehicle is

Dr a g is a pr odu ct of in com plet e br a ke

st

opped.

Sever e dr a g

ca n ch a r t h e br a ke linin g all t h e wa y

t h r ou gh.

dr

a n d br a ke com pon ent s will be ext r em ely h ot. In

sever e ca ses, t h e linin g m a y gen er at e sm oke a s it

ch a r s fr om

It ca n also dist ort a n d scor e r ot or s a n d

um s t o t h e point of r epla cem ent. Th e wh eels, tir es

over h eatin g. ca u ses of br a ke dr a g a r e:

Comm on

Seized or im pr operly a dju st ed pa r kin g br a ke

ca bles

Loose/wor n wh eel bea rin g

Seized caliper or wh eel cylin der pist on

Caliper bin din g on dam a ged or missin g a nti-r at - tle clips or bu shin gs

Loose caliper m ou ntin g

Dr um br a ke sh oes bin din g on wor n/dam a ged

su pport plat es

Mis-a ssem bled com pon ent s

Lon g boost er out put r od

If

br a ke dr a g occu r s at all wh eels, t h e pr oblem

m a y be r elat ed t o a blocked m a st er cylin der r et u r n

boost er (bin ds-does n ot r elea se).

port, or fa ult y power

BRAKE FADE

over h eatin g over h eatin g

ca

a n d r esultin g fa de ca n also be ca u sed by ridin g t h e

deceler ation st ops br a kin g on st eep

Br a ke Dr a g in form ation

in a sh ort tim e spa n, or con st a nt

br

Br a ke fa de is u su ally a pr odu ct of

u sed by br a ke dr a g. H owever, br a ke

a ke pedal, m a kin g r epeat ed high

m ou nt ain r oa ds. Refer t o t h e in t his section for ca u ses.

BRAKE PULL

F r ont br a ke pull con dition

could r esult fr om:

linin g in on e caliper

Cont amin at ed

Seized caliper

pist on

Bin din g caliper

Loose caliper

Dam a ged a nti-r attle clips

Im pr oper br a ke sh oes

Dam a ged r ot or

A wor n,

com pon ent

dam a ged wh eel bea rin g or su spen sion a r e fu rt h er ca u ses of pull. A dam a ged

BR/BE

BRAKES

5 - 7

HYDRAULIC/MECHANICAL (Continued)

fr ont tir e (br uised, ply sepa r ation ) ca n also ca u se

pull.

con di-

tion is wh er e dir ection of pull ch a n ges a ft er a few

is a com bin ation of br a ke dr a g fol- on e of t h e br a ke u nit s.

st

lowed

A comm on a n d fr equ ently misdia gn osed pull

ops.

Th e ca u se by fa de at

As t h e dr a ggin g br a ke over h eat s, efficien cy is so

r edu ced t h at fa de occu r s. Sin ce t h e opposit e br a ke

u nit is still fu n ctionin g n orm ally, it s br a kin g effect is

m

a gnified.

This ca u ses pull t o swit ch dir ection in

fa

vor

of t h e n orm ally fu n ctionin g br a ke u nit.

An

a ddition al point wh en dia gn osin g a ch a n ge in

pull

con dition con cer n s br a ke cool down. Rem em ber

pull will r et u r n t o t h e origin al dir ection, if t h e

dr a ggin g br a ke u nit is allowed t o cool down (a n d is

n ot seriou sly dam a ged).

t h at

REAR BRAKE GRAB OR PULL

Rea r gr a b or pull is u su ally ca u sed by im pr operly

a

dju st ed or

seized pa r kin g br a ke ca bles, cont ami-

n

at ed linin g, bent or bin din g sh oes a n d su pport

plat es, or im pr operly a ssem bled com pon ent s. This is pa rticula rly t r u e wh en only on e r ea r wh eel is

in volved. H owever, wh en

a ffect ed,

could be

wh eels a r e

t h e m a st er cylin der or pr oportionin g valve at fa ult.

bot h

r ea r

BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES

This

con dition is gen er ally ca u sed by wat er soa ked

linin g.

If t h e linin g is only wet, it ca n be dried by

a

mile or two. H owever, if t h e linin g is bot h soa ked a n d dirt cont amin at ed, clea nin g a n d/or r epla cem ent will be n ecessa r y.

drivin g wit h t h e br a kes

ver y lightly a pplied for

BRAKE LINING CONTAMINATION

Br a ke linin g cont amin ation is m ostly a pr odu ct of

lea kin g caliper s or wh eel cylin der s, wor n seals, driv-

in g t h r ou gh deep wat er pu ddles, or linin g t h at h a s

becom e cover ed wit h gr ea se a n d grit du rin g r epair.

Cont amin at ed linin g sh ould be r epla ced t o a void fu r -

t h er br a ke pr oblem s.

WHEEL AND TIRE