Login- Download PDF Manual
-
(1) Install new pinion seal with Installer 8896
(2) Apply a light coat of teflon sealant to the pin-
(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer and new pinion nut. (5) Hold pinion flange with Flange Wrench 8979
(Fig. 24) and tighten pinion nut until pinion end play is taken up.(6) Rotate pinion several times to seat bearings. (7) Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement. Tighten pinion nut in small incre-
DR PINION SEAL (Continued)
REAR AXLE - 11 1/2 AA
3 - 141
OPERATION
During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 25).
Fig.23PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
Fig.25DIFFERENTIAL-STRAIGHTAHEADDRIVING 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE
When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 26). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.
Fig.24FLANGEWRENCH
1 - FLANGE WRENCH 2 - PINION FLANGE
ments, until pinion rotating torque is 0.40-0.57 N·m (3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shafts. (10) Install propeller shaft with reference marks
aligned.
(11) Check differential fluid level.
DIFFERENTIAL DESCRIPTION
The differential case is a one-piece design. The dif- ferential pinion shaft is retained with a snap ring. Differential bearing preload and ring gear backlash is adjusted by the use of adjusters. The adjuster are between the differential bearings and the differential housing. Pinion bearing preload is set and main- tained by the use of a collapsible spacer. The stamped steel cover provides a means for inspection and servicing the differential.
Fig.26DIFFERENTIAL-ONTURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
REAR AXLE - 11 1/2 AA
3 - 142
DIFFERENTIAL (Continued) REMOVALDR
(1) Remove fill hole plug from the differential
housing cover.
the lubricant.
(Fig. 27).
(2) Remove differential housing cover and drain
(3) Remove axle shafts. (4) Remove adjuster lock bolts and adjuster locks
Fig.28ADJUSTERS
1 - BEARING CUP 2 - ADJUSTER 3 - BEARING CUP 4 - ADJUSTER
Fig.27ADJUSTERLOCKS
1 - LOCK BOLT 2 - ADJUSTER LOCK 3 - ADJUSTER 4 - BEARING CAP
(5) Mark bearing caps left and right for installa-
(6) Remove bearing cap bolts and remove bearing
tion reference.
caps.
(7) Loosen differential bearing adjusters (Fig. 28)
with Spanner Wrench 8883.
(8) Remove differential case from the housing. (9) Remove bearing cups and tag them left and
right for installation reference.
DISASSEMBLY
(1) Remove ring gear. (2) Remove pinion shaft with a hammer and punch from the side with the hole in the pinion shaft (Fig. 29).
(3) Rotate one pinion gear with thrust washer (Fig. 30) to the differential window and remove the gear.
Fig.29PINIONSHAFT
1 - PINION GEAR 2 - PINION SHAFT 3 - EXCITER RING
DR DIFFERENTIAL (Continued)
REAR AXLE - 11 1/2 AA
3 - 143
Fig.30FIRSTPINIONGEAR
Fig.32SIDEGEARS
1 - DIFFERENTIAL WINDOW 2 - PINION GEAR 3 - THRUST WASHER
(4) Rotate the other pinion gear with thrust washer (Fig. 31) to the differential window and remove the gear.
1 - SIDE GEAR 2 - SIDE GEAR 3 - PINION GEARS
ASSEMBLY
NOTE: If the same gears and thrust washers are being used, install them into their orignial locations.
(1) Lubricate all differential components with axle
(2) Install differential side gears and thrust wash-
lubricant.
ers (Fig. 33).
Fig.31SECONDPINIONGEAR
1 - DIFFERENTIAL WINDOW 2 - THRUST WASHER 3 - PINION GEAR
(5) Remove differential side gears and thrust
washers (Fig. 32).
Fig.33SIDEGEAR
1 - DIFFERENTIAL WINDOW 2 - SIDE GEAR
REAR AXLE - 11 1/2 AA
3 - 144
DIFFERENTIAL (Continued)(3) Install first pinion gear into the differential window and side gears. Rotate the pinion gear to the back of the case (Fig. 34).
DR
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or gasoline for cleaning.
(2) Lubricate differential case bearing. (3) Install differential case with bearings cups into
the housing.
NOTE: A light coat of grease on the cups will hold them in place during installation.
(4) Install bearing caps and bolts (Fig. 36). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this time.
Fig.34PINIONGEAR
1 - DIFFERENTIAL WINDOW 2 - SIDE GEARS 3 - PINION GEAR
(4) Install
the other pinion gear and thrust washer. Rotate the gears to align hole in the pinion gears with hole in the differential case.
(5) Slide pinion shaft into the case and through the pinion gears. Tap the shaft to seat the pinion shaft snap-ring into the case (Fig. 35).
Fig.36CASEBEARINGCAP
1 - DIFFERENTIAL HOUSING 2 - BEARING CAP 3 - ADJUSTER
Fig.35PINIONSHAFTINSTALLATION
1 - SNAP RING 2 - SIDE GEAR 3 - PINION GEAR 4 - PINION SHAFT
(6) Install ring gear.
(5) Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential bearings/cups.
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
DR DIFFERENTIAL (Continued)
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear
side adjuster
firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup. (13) Tighten pinion gear side adjuster an additional: † New Bearings 6 Adjuster Holes † Original Bearings 4 Adjuster Holes (14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 281 N·m (207 ft.
(16) Tighten adjuster lock bolts to 25 N·m (18 ft.
lbs.).
lbs.) (Fig. 37).
Fig.37ADJUSTERLOCKBOLT
1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT 4 - BEARING CAP BOLT
(17) Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for pro- cedure.
(18) Install axle shaft gasket and install axle
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N·m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N·m (24 ft.
shafts.
lbs.).
REAR AXLE - 11 1/2 AA
3 - 145
DIFFERENTIAL TRAC-RITE DESCRIPTION
The Trac-Rite™ differential is a helical gear differ- ential. The differential has two side gears, six pinion gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly only if damaged, but can be disassembled for cleaning. The assembly should be cleaned every time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on that side are forced toward the pinion brake shoes. The pinion brake shoes then cause frictional drag on the opposite pinion gears and the side gear. These friction forces transfer the power to the opposite wheel. Once the frictional forces are overcome, differ- entiation will occur. The torque will be continually biased by the frictional forces to the high traction wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts. (2) Remove differential case cover locating screws
(Fig. 38).
Fig.38LOCATIONSCREWS
1 - DIFFERENTIAL COVER 2 - LOCATION SCREWS
(3) Remove differential case cover. (4) Remove side gear and thrust washer (Fig. 39).
REAR AXLE - 11 1/2 AA
3 - 146
DIFFERENTIAL TRAC-RITE (Continued)NOTE: Mark all component locations.
DR
Fig.39SIDEGEARANDTHRUSTWASHER
1 - SIDE GEAR 2 - THRUST WASHER
(5) Remove three pinion brake shoes (Fig. 40).
Fig.40PINIONBRAKESHOES
1 - BRAKE SHOES 2 - PINION GEARS
(6) Remove six pinion gears (Fig. 41).
Fig.41PINIONGEARS
1 - PINION GEARS 2 - SIDE GEAR
(7) Remove remaining side gear thrust washer and
spacer.
(8) Remove remaining three pinion brake shoes.
CLEANING
Clean the differential case and gears with light oil
or a lint free cloth.
NOTE: Never use water, steam, kerosene or gaso- line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be smoothed with 400 grit emery cloth and polished out with crocus cloth.
(1) Inspect pinion gears teeth for chips and cracks
(2) Inspect pinion gears shafts and brake shoes for
scratches, flat-spots or worn (Fig. 42).
(3) Inspect side gears teeth for chips and cracks
(4) Inspect pinion and side gear bores for scratches
(Fig. 42).
(Fig. 43).
(Fig. 44).
NOTE: If any damage is found the differential must be replaced as an assembly. Individual components can not be replaced separately.
DR DIFFERENTIAL TRAC-RITE (Continued)
REAR AXLE - 11 1/2 AA
3 - 147
Fig.42PINIONGEARANDBRAKESHOE
1 - BRAKE SHOES 2 - PINION GEAR 3 - PINION SHAFT
Fig.44PINION/SIDEGEARBORE
1 - PINION BORES 2 - SIDE GEAR BORE
(3) Install side gear thrust washer, side gear and
spacer (Fig. 45).
Fig.43SIDEGEARS
1 - THRUST WASHERS 2 - SPACER 3 - SIDE GEARS
ASSEMBLY
NOTE: Install all component in their original loca- tions.
(1) Lubricate all gears and differential bores with
differential lubricant.
case bores.
(2) Install one set of pinion brake shoes into the
NOTE: Brake shoes can be installed upside down, but if install wrong pinion gear will not fit.
Fig.45SIDEGEARANDSPACER
1 - SPACER 2 - SIDE SPACER
REAR AXLE - 11 1/2 AA
3 - 148
DIFFERENTIAL TRAC-RITE (Continued)DR
(4) Install one set of pinion gears into the bores next to the brake shoes, with the pinion shaft facing up.
(5) Install other side gear and thrust washer. (6) Install other set of pinion gears into the brake
shoes in the case.
gears shafts (Fig. 46).
(7) Install other set of brake shoes onto the pinion
Fig.46PINIONBRAKESHOES
1 - BRAKE SHOES 2 - PINION GEARS
(8) Install differential cover and location screws. (9) Install new ring gear bolts and tighten to 237
N·m (175 ft. lbs.).
DIFFERENTIAL CASE BEARINGS REMOVAL
(1) Remove differential case from the housing. (2) Install Plug 8964 into the end of the case. (3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 47).
INSTALLATION
(1) Install differenial case bearings with Installer
8965 and Handle C-4171 (Fig. 48).
(2) Install differentail case into housing.
Fig.47DIFFERENTIALCASEBEARING
1 - BRIDGE 2 - SPLITTER 3 - BEARING 4 - PLUG
Fig.48DIFFERENTIALCASEBEARINGS
1 - HANDLE 2 - DIFFERENTIAL CASE 3 - BEARING 4 - INSTALLER
DR
REAR AXLE - 11 1/2 AA
3 - 149
(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
PINION GEAR/RING GEAR/ TONE RING REMOVAL
NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from the housing. (4) Place differential on Plug 8964. Drive exciter ring off the differential case with a hammer and punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not being replaced.
Fig.50RINGGEAR
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flange nut.
Fig.49EXCITERRING
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - PUNCH 4 - EXCITER RING
Fig.51FLANGEWRENCH
(5) Place differential case in a vise with soft metal
jaw protectors
1 - PINION FLANGE 2 - FLANGE WRENCH
REAR AXLE - 11 1/2 AA
3 - 150
PINION GEAR/RING GEAR/TONE RING (Continued)DR
(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 52).
(14) Remove rear pinion bearing with Bearing
Splitter 1130 and a press (Fig. 54).
Fig.52PINIONFLANGEPULLER
Fig.54BEARINGSPLITTER
1 - PINION FLANGE 2 - PULLER
1 - PINION BEARING 2 - SPLITTER
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the housing with a punch and hammer, and discard cup.
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the if bearing is
housing with a punch and hammer, going to be replaced.
INSTALLATION
(1) Install new front pinion bearing cup (Fig. 55)
with Installer 8960 and Handle C-4171.
(10) Remove pinion gear from housing with Pinion
Driver 8977 and a hammer (Fig. 53).
NOTE: Thread the driver on the pinion shaft till it bottoms out.
Fig.53PINIONDRIVER
1 - PINION SHAFT 2 - PINION DRIVER
(11) Remove pinion seal with a slide hammer or
(12) Remove front pinion bearing and discard bear-
pry bar.
ing.
CAUTION: Do not reuse front pinion bearing/cup.
Fig.55FRONTPINIONBEARINGCUP
(13) Remove collapsible spacer from the pinion
shaft.
1 - INSTALLER 2 - HANDLE
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 11 1/2 AA
3 - 151
(2) Install new rear pinion bearing cup (Fig. 56)
with Installer 8968 and Handle C-4171.
(4) Install rear pinion bearing (Fig. 58) with
Installer D-389 and a press.
Fig.56REARPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
(3) Install pinion depth shim (Fig. 57) on the pin-
ion gear shaft.
Fig.58REARPINIONBEARING
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
(5) Install new collapsible spacer (Fig. 59).
Fig.57PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
Fig.59COLLAPSIBLESPACER
1 - COLAPSIBLE SPACER 2 - PINION GEAR 3 - REAR PINION BEARING
(6) Lubricate pinion and bearings.
REAR AXLE - 11 1/2 AA
3 - 152
PINION GEAR/RING GEAR/TONE RING (Continued)(7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (Fig. 60).
DR
Fig.60PINIONGEARINSTALLER
1 - INSTALLER 2 - DIFFERENTIAL HOUSING
(8) Install new pinion seal (Fig. 61) with Installer
8896 and Handle C-4171.
Fig.62FLANGEWRENCH
1 - FLANGE WRENCH 2 - PINION FLANGE
† New Pinion Bearings: 1.7-2.8 N·m (15-25 in. lbs.)† Original Pinion Bearings: 1.1-2.2 N·m (10-20
in. lbs.)Fig.61PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange
onto the pinion, until a few threads are showing.
(11) Install pinion flange washer and new pinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
(Fig. 62) and tighten pinion nut until pinion end play is taken up.(13) Rotate pinion several times to seat bearings. (14) Measure pinion rotating torque with an inch pound torque wrench (Fig. 63). Tighten pinion nut in small increments until pinion rotating torque is:
Fig.63PINIONROTATINGTORQUE
1 - PINION FLANGE 2 - TORQUE WRENCH
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start two new ring gear bolts.
(17) Install the rest of the new ring gear bolts and
tighten them alternately to seat the ring gear.
(18) Torque ring gear bolts to 237 N·m (175 ft.
lbs.).
DR PINION GEAR/RING GEAR/TONE RING (Continued)
(19) If exciter ring was removed, position differen- tial assembly on differential Plug 8965 (Fig. 64) and place exciter ring on the differential case.
REAR AXLE - 11 1/2 AA
3 - 153
Fig.64EXCITERRING
1 - EXCITER RING 2 - RING GEAR 3 - DIFFERENTIAL PLUG 4 - DIFFERENTIAL CASE
(20) Install the exciter ring on the differential case evenly with a hammer and brass punch (Fig. 65). Drive the ring down until it is seated against the ring gear.
CAUTION: Do not damage exciter ring teeth during installation.
(21) Install differential in housing and verify gear
backlash and gear contact pattern.
Fig.65EXCITERRINGINSTALLATION
1 - EXCITER RING 2 - PUNSH 3 - RING GEAR
(22) Measure final rotating torque with an inch pound torque wrench. The final pinion rotating torque plus differential case bearing preload is: † New Bearings: 3.4-5.6 N·m (30-50 in. lbs.) † Original Bearings: 2.8-5.1 N·m (25-45 in. lbs.) (23) Install axle shafts. (24) Install the propeller shaft with the reference
marks aligned.
(25) Install differential cover with gasket and
tighten bolts to 40 N·m (30 ft. lbs.).
(26) Fill differential with fluid and tighten fill plug
to 32 N·m (24 ft. lbs.).
DR
BRAKES
5 - 1
BRAKES
TABLE OF CONTENTS
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
page
page
BRAKES - BASE
TABLE OF CONTENTS
page
page
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - PRESSURE
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTABLE PEDAL SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6HYDRAULIC/MECHANICAL
SPECIFICATIONS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVALREMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 12
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATIONINSTALLATION - REAR . . . . . . . . . . . . . . . . . 16
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 16DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 16INSTALLATION
SPECIFICATIONS - TORQUE CHART BASE BRAKE
. . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . 7INSTALLATION - REAR . . . . . . . . . . . . . . . . . 17
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 17BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE - ISO FLARING . . . 7REMOVAL
REMOVAL - REAR BRAKE HOSE REMOVAL - REAR TUBE / HOSE
DISC BRAKE CALIPER ADAPTER MOUNT
. . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL - REAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
. . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . 8
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . 9REMOVAL - FRONT HOSE
INSTALLATION
INSTALLATION - REAR BRAKE HOSE INSTALLATION - REAR TUBE / HOSE
. . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . 9INSTALLATION - FRONT BRAKE HOSE
BRAKE PADS/SHOES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10DISC BRAKE CALIPERS
DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 18
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19BRAKE JUNCTION BLOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19MASTER CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 - 2
BRAKES - BASE
DR
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER . . . . . . . . . . . 20
STANDARD PROCEDURE - MASTER
SUPPORT PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29CYLINDER BLEEDING . . . . . . . . . . . . . . . . . . 20
PARKING BRAKE
REMOVAL
REMOVAL - ALL EXCEPT HYDROBOOST . . . 21
. . . . . . . . . . . . . 21
REMOVAL - HYDROBOOSTINSTALLATION
INSTALLATION - ALL EXCEPT
HYDROBOOST . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION - HYDROBOOST . . . . . . . . . . 22PEDAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23ADJUSTABLE PEDAL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25HYDRO-BOOST BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STANDARD PROCEDURE - BLEEDING . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27ROTORS
REMOVAL
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 28INSTALLATION
INSTALLATION - REAR . . . . . . . . . . . . . . . . . 28
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 29BRAKES - BASE DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM
Base brake components consist of the brake shoes, calipers, wheel cylinders, brake drums, rotors, brake lines, master cylinder, booster, and parking brake components.
Brake diagnosis involves determining if the prob- lem is related to a mechanical, hydraulic, or vacuum operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged wheels and worn, damaged, or underinflated tires can cause pull, shudder, vibration, and a condition similar to grab.
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL - REAR PARK BRAKE CABLE . . . 31
REMOVAL - RIGHT REAR CABLE . . . . . . . . . 31
REMOVAL - LEFT REAR CABLE . . . . . . . . . . 32INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - REAR PARK BRAKE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . 32
. . . . . . 33INSTALLATION - RIGHT REAR CABLE INSTALLATION - LEFT REAR CABLE
SHOES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CLEANING - REAR DRUM IN HAT BRAKE . . . . 33
INSPECTION - REAR DRUM IN HAT BRAKE . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
ADJUSTMENTSADJUSTMENT - PARKING BRAKE SHOES ADJUSTMENT - WITH ADJUSTING TOOL
. . 34
. . . 36PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 37
RELEASE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38(2) If complaint was based on noise when braking, check suspension components. Jounce front and rear of vehicle and listen for noise that might be caused by loose, worn or damaged suspension or steering components.
(3) Inspect brake fluid level and condition. Note that the brake reservoir fluid level will decrease in proportion to normal lining wear. 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 abnormally low, look for evi- dence of leaks at calipers, wheel cylinders, brake lines, and master cylinder.
(b) If fluid appears contaminated, drain out a sample to examine. System will have to be flushed if fluid is separated into layers, or contains a sub- stance other than brake fluid. The system seals
DR BRAKES - BASE (Continued)
and cups will also have to be replaced after flush- ing. Use clean brake fluid to flush the system. (4) Check parking brake operation. Verify free movement and full release of cables and pedal. Also note if vehicle was being operated with parking brake partially applied.
(5) Check brake pedal operation. Verify that pedal does not bind and has adequate free play. If pedal lacks free play, check pedal and power booster for being loose or for bind condition. Do not road test until condition is corrected.
(6) Check booster vacuum check valve and hose. (7) If components checked appear OK, road test
the vehicle.
BRAKES - BASE
5 - 3
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or badly worn. The power booster or check valve could also be faulty.
PEDAL PULSATION
Pedal pulsation is caused by components that are
loose, or beyond tolerance limits.
The primary cause of pulsation are disc brake rotors with excessive lateral runout or thickness vari- ation, or out of round brake drums. Other causes are loose wheel bearings or calipers and worn, damaged tires.
ROAD TESTING
(1) If complaint involved low brake pedal, pump pedal and note if it comes back up to normal height. (2) Check brake pedal response with transmission in Neutral and engine running. Pedal should remain firm under constant foot pressure.
(3) During road test, make normal and firm brake stops in 25-40 mph range. Note faulty brake opera- tion such as low pedal, hard pedal, fade, pedal pulsa- tion, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking
brake only and note grab, drag, noise, etc.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot pressure is generally the result of a system leak. The leak point could be at a brake line, fitting, hose, or caliper/wheel cylinder. If leakage is severe, fluid will be evident at or around the leaking component.
Internal leakage (seal by-pass) in the master cylin- der caused by worn or damaged piston cups, may also be the problem cause.
An internal leak in the ABS or RWAL system may
also be the problem with no physical evidence.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev- eral times. If the pedal comes back up worn linings, rotors, drums, or rear brakes out of adjustment are the most likely causes. The proper course of action is to inspect and replace all worn component and make the proper adjustments.
SPONGY PEDAL
A spongy pedal is most often caused by air in the system. However, thin brake drums or substandard brake lines and hoses can also cause a spongy pedal. The proper course of action is to bleed the system, and replace thin drums and substandard quality brake hoses if suspected.
NOTE: Some pedal pulsation may be felt during ABS activation.
BRAKE DRAG
Brake drag occurs when the lining is in constant contact with the rotor or drum. Drag can occur at one wheel, all wheels, fronts only, or rears only.
Drag is a product of incomplete brake shoe release. Drag can be minor or severe enough to overheat the linings, rotors and drums.
Minor drag will usually cause slight surface char- ring of the lining. It can also generate hard spots in rotors and drums from the overheat-cool down pro- cess. In most cases, the rotors, drums, wheels and tires are quite warm to the touch after the vehicle is stopped.
Severe drag can char the brake lining all the way through. It can also distort and score rotors and drums to the point of replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the lining may generate smoke as it chars from overheating.
slide surfaces.
Common causes of brake drag are: † Seized or improperly adjusted parking brake cables.† Loose/worn wheel bearing. † Seized caliper or wheel cylinder piston. † Caliper binding on corroded bushings or rusted † Loose caliper mounting. † Drum brake shoes binding on worn/damaged † Mis-assembled components. † Long booster output rod. If brake drag occurs at all wheels, the problem may be related to a blocked master cylinder return port, or faulty power booster (binds-does not release).
support plates.
BRAKE FADE
Brake fade is usually a product of overheating caused by brake drag. However, brake overheating
BRAKES - BASE
5 - 4
BRAKES - BASE (Continued)and resulting fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a short time span, or constant braking on steep mountain roads. Refer to the Brake Drag information in this section for causes.
BRAKE PULL Front brake pull condition could result from: † Contaminated lining in one caliper † Seized caliper piston † Binding caliper † Loose caliper † Rusty caliper slide surfaces † Improper brake shoes † Damaged rotor A worn, damaged wheel bearing or suspension component are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull.
A common and frequently misdiagnosed pull condi- tion is where direction of pull changes after a few stops. The cause is a combination of brake drag fol- lowed by fade at one of the brake units.
As the dragging brake overheats, efficiency is so reduced that fade occurs. Since the opposite brake unit is still functioning normally, its braking effect is magnified. This causes pull to switch direction in favor of the normally functioning brake unit.
An additional point when diagnosing a change in pull condition concerns brake cool down. Remember that pull will return to the original direction, if the dragging brake unit is allowed to cool down (and is not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pull is usually caused by improperly adjusted or seized parking brake cables, contami- nated lining, bent or binding shoes and support plates, or improperly assembled components. This is particularly true when only one rear wheel is involved. However, when both rear wheels are affected, the master cylinder or proportioning valve could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES
This condition is generally caused by water soaked lining. If the lining is only wet, it can be dried by driving with the brakes very lightly applied for a mile or two. However, if the lining is both soaked and dirt contaminated, cleaning and/or replacement will be necessary.
BRAKE LINING CONTAMINATION
Brake lining contamination is mostly a product of leaking calipers or wheel cylinders, worn seals, driv- ing through deep water puddles, or lining that has
DR
become covered with grease and grit during repair. Contaminated lining should be replaced to avoid fur- ther brake problems.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components may actually be caused by a wheel or tire problem. A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can produce a grab-like condition as the tire loses and recovers traction. Flat-spotted tires can cause vibra- tion and generate shudder during brake operation. A tire with internal damage such as a severe bruise, cut, or ply separation can cause pull and vibration.
BRAKE NOISES
Some brake noise is common with rear drum brakes and on some disc brakes during the first few stops after a vehicle has been parked overnight or stored. This is primarily due to the formation of trace corrosion (light rust) on metal surfaces. This light corrosion is typically cleared from the metal surfaces after a few brake applications causing the noise to subside.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oil. Glazed linings and rotors with hard spots can also contribute to squeak. Dirt and foreign material embedded in the brake lining will also cause squeak/ squeal.
A very loud squeak or squeal is frequently a sign of severely worn brake lining. If the lining has worn through to the brake shoes in spots, metal-to-metal contact occurs. If the condition is allowed to continue, rotors and drums can become so scored that replace- ment is necessary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn components, or glazed/burnt lining. Rotors with hard spots can also contribute to chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre- quently not caused by brake components. In many cases, such noises are caused by loose or damaged steering, suspension, or engine components. However, calipers that bind on the slide surfaces can generate a thump or clunk noise. In addition, worn out, improperly adjusted, or improperly assembled rear brake shoes can also produce a thump noise.
DR BRAKES - BASE (Continued) STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times.
(1) Remove reservoir filler caps and fill reservoir. (2) If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding.
(3) Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid (Fig. 1). Be sure end of bleed hose is immersed in fluid.
BRAKES - BASE
5 - 5
tank manufacturers pressure recommendations. Gen- erally, a tank pressure of 15-20 psi is sufficient for bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl- inder adapter. The wrong adapter can lead to leak- age, or drawing air back into the system.
SPECIAL TOOLS
BASE BRAKES
INSTALLER,BRAKECALIPERDUSTBOOTC-4340
INSTALLER,BRAKECALIPERDUSTBOOT
C-3716-A
Fig.1BleedHoseSetup
1 - BLEED HOSE 2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
(4) Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel.
STANDARD PROCEDURE - PRESSURE BLEEDING
Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times.
Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the
HANDLEC-4171
BRAKES - BASE
5 - 6
BRAKES - BASE (Continued)DR
CAP,MASTERCYLINDERPRESSUREBLEED6921
GAUGE,BRAKESAFE-SETC-3919
ADJUSTABLE PEDAL SWITCH REMOVAL
(1) Remove the lower drivers side bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL DR SIDE BEZEL - REMOVAL).
(2) Disconnect the electrical connector from the
adjustable pedal switch.
(3) Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards (Fig. 2).
INSTALLATION
(1) Install the switch to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel.
Fig.2LOWERDRIVERSSIDEBEZEL
1 - SCREWS (2) 2 - ADJUSTABLE PEDAL SWITCH 3 - PEDAL SWITCH ELECTRICAL CONNECTOR 4 - BEZEL
(2) Reconnect
the
electrical
connector
to
the
adjustable pedal switch.
(3) Install the lower drivers side bezel
(Fig. 2) (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL DR SIDE BEZEL - INSTALLA- TION).
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Brake Booster Mounting Nuts Master Cylinder Mounting Nuts
Caliper
Mounting Pins
Caliper
Adapter Mounting Bolts
Junction Block Bolts To Frame
Brake Pedal Assembly Bracket
Nuts
N·m 38
18
32
176
10
28
Ft. Lbs.
28
—
24
130
7.5
21
In. Lbs.
—
160
—
—
—
—
DR HYDRAULIC/MECHANICAL (Continued)
DESCRIPTION Support Plate
Mounting Bolts/Nuts Brake Line Fittings
Master Cylinder
Brake Line Fittings
Junction Block
Caliper
Brake Line Banjo Bolt
Brake Hose
Front Bolts To Frame
Brake Hose Front Fitting Brake Hose Rear Fitting
Parking Brake Pedal Assembly
Hub/Bearing
Bolts
N·m 64
19
19
27
10
19
19
19
163BRAKES - BASE
5 - 7
Ft. Lbs.
In. Lbs.
47
14
14
20
7.5
14
14
14
120—
170
170
245
—
250
250
250
—BASE BRAKE
BRAKE LINES
SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Front Disc Brake Caliper Type Rear Disc Brake Caliper Type Front Disc Brake Caliper Front Disc Brake Rotor
Front/Rear Disc Brake Rotor Max. Runout Front/Rear Disc Brake Rotor Max. Thickness Variation Minimum Front Rotor Thickness Mininium Rear Rotor Thickness Rear Disc Brake Caliper Rear Disc Brake Rotor Brake Booster Type Gasoline Engines
Dual Piston Sliding
Single Piston Sliding
54 mm (2.00 in.) 336×28 mm (13.2×1.1
in.) 0.127 mm (0.005 in.)0.025 mm (0.001 in.)
26.4 mm (1.039 in.)
28.39 mm (1.117 in)
1x54 mm (2.12 in) 350x22 mm (.86 in) Vacuum Dual Diaphragm
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE INVERTED FLARING
A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available.
(1) Cut off damaged tube with Tubing Cutter. (2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on the tube. (4) Insert tube in flaring tool. (5) Place gauge form over the end of the tube. (6) Push tubing through flaring tool
jaws until tube contacts recessed notch in gauge that matches tube diameter.
(7) Tighten the tool bar on the tube (8) Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flar- ing screw in recess of compression disc (Fig. 3).
(9) Tighten tool handle until plug gauge
is squarely seated on jaws of flaring tool. This will start the inverted flare.
(10) Remove the plug gauge and complete the
inverted flare.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel
BRAKES - BASE
5 - 8
BRAKE LINES (Continued)DR
Fig.3InvertedFlareTools
tube can be used for emergency repair when factory replacement parts are not readily available.
To make a ISO flare use an ISO flaring tool kit. (1) Cut off damaged tube with Tubing Cutter. (2) Remove any burrs from the inside of the tube. (3) Install tube nut on the tube. (4) Position the tube in the flaring tool flush with the top of the tool bar (Fig. 4). Then tighten the tool bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor. (7) Align the adaptor and yoke screw over the tube
(Fig. 4).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
REMOVAL
REMOVAL - REAR BRAKE HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle. (3) Remove the brake line from the hose at the
frame (Fig. 5).
(4) Remove the brake hose clip at the top of the
hose located at the frame (Fig. 5).
(5) Remove the vent tube (Fig. 6). (6) Remove the two brake lines at the bottom of
the hose located at the axle (Fig. 6).
(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 6).
(8) Remove the hose.
Fig.4ISOFlaring
1 - ADAPTER 2 - LUBRICATE HERE 3 - PILOT 4 - FLUSH WITH BAR 5 - TUBING 6 - BAR ASSEMBLY
Fig.5BRAKELINECLIP
1 - BRAKE HOSE 2 - CLIP 3 - BRAKE LINE
REMOVAL - REAR TUBE / HOSE ASSEMBLY
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle. (3) Remove the brake line located at the axle. (4) Remove the mounting bolt for the brake hose
at the axle (Fig. 7).
DR BRAKE LINES (Continued)
BRAKES - BASE
5 - 9
Fig.6REARHOSE
1 - BRAKE HOSE 2 - VENT HOSE 3 - BRAKE LINES
Fig.8BRAKEHOSEMOUNTEDPASSENGERSIDE 1 - MOUNTING BOLT 2 - BRAKE HOSE 3 - BANJO BOLT 4 - WHEEL SPEED SENSOR WIRE
(5) Remove the banjo bolt at the caliper (Fig. 7). (6) Remove the hose.
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose. (2) Install the mounting bolt for the brake hose at
the axle (Fig. 6).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 6).
(4) Install the vent tube (Fig. 6). (5) Install the brake hose clip at the top of the
hose located at the frame (Fig. 5).
(6) Install the brake line to the hose at the frame
(Fig. 5).
(7) Lower the vehicle and remove the support. (8) Remove the prop rod. (9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR TUBE / HOSE ASSEMBLY
(1) Install the hose. (2) Install the banjo bolt at the caliper (Fig. 7). (3) Install the mounting bolt for the brake hose at
(4) Install the brake line located at the axle. (5) Lower the vehicle and remove the support. (6) Remove the prop rod. (7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose. (2) Install the mounting bolt for the brake hose at
the frame (Fig. 9).
(1) Install a prop rod on the brake pedal to keep
the axle (Fig. 7).
Fig.7BRAKELINEWITHRUBBERHOSE
1 - BANJO BOLT 2 - MOUNTING BOLT 3 - REAR TUBE / HOSE ASSEMBLY
REMOVAL - FRONT HOSE
pressure on the brake system.
(2) Raise and support vehicle. (3) Remove the tire and wheel assembly. (4) Remove the brake hose from the brake line
located at the frame (Fig. 8).
(5) Remove the brake hose banjo bolt at the caliper
(Fig. 8).
(6) Remove the mounting bolt securing the brake hose to the frame and remove the wheel speed sensor wire from the brake hose (Fig. 8).
(7) Remove the hose.
BRAKES - BASE
5 - 10
BRAKE LINES (Continued)DR
(3) Install the brake hose banjo bolt at the caliper
(Fig. 8).
brake hose (Fig. 8).
(4) Reinstall the wheel speed sensor wire to the
(5) Remove the support and lower the vehicle.
Fig.10Caliper
1 - CALIPER 2 - CALIPER ADAPTER
Fig.9BRAKEHOSEMOUNTDRIVERSSIDE
1 - MOUNTING BOLT 2 - WHEEL SPEED SENSOR WIRE 3 - BRAKE HOSE
(6) Remove the prop rod from the brake pedal. (7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS/SHOES REMOVAL
(1) Raise and support vehicle. (2) Remove the wheel and tire assemblies. (3) Compress the caliper. (4) Remove the caliper, (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(5) Remove the caliper by tilting the top up and off
the caliper adapter (Fig. 10).
Fig.11DISCBRAKECALIPER-FRONT
1 - STEERING KNUCKLE 2 - DISC BRAKE CALIPER 3 - CALIPER MOUNTING ADAPTER 4 - DISC BRAKE ROTOR
NOTE: Do not allow brake hose to support caliper assembly.
INSTALLATION
(6) Support and hang the caliper. (Fig. 11) (7) Remove the inboard brake shoe from the cali-
per adapter (Fig. 12).
per adapter (Fig. 13).
(8) Remove the outboard brake shoe from the cali-
(9) Remove the anti-rattle springs from the caliper
adapter (Fig. 14) and (Fig. 15).
(1) Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and cal- iper piston.
(2) Clean caliper mounting adapter and anti-rattle
(3) Lubricate anti-rattle springs with Mopar brake
springs.
grease.
(4) Install anti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
NOTE: Anti-rattle springs are not interchangeable.
(5) Install inboard brake shoe in adapter.
DR BRAKE PADS/SHOES (Continued)
BRAKES - BASE
5 - 11
Fig.14TopAnti-RattleSpring
1 - CALIPER ADAPTER 2 - ANTI-RATTLE SPRING
Fig.12InboardBrakeShoe
1 - INBOARD SHOE 2 - CALIPER ADAPTER
Fig.15BottomAnti-RattleSpring
1 - ANTI-RATTLE SPRING 2 - CALIPER ADAPTER
Fig.13OutboardBrakeShoe
1 - OUTBOARD SHOE 2 - CALIPER ADAPTER
(6) Install outboard brake shoe in adapter. (7) Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter.
(8) Install caliper,
(Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(9) Install wheel and tire assemblies and lower vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(10) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(11) Top off master cylinder fluid level.
DISC BRAKE CALIPERS DESCRIPTION
The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compen- sation for lining wear.
BRAKES - BASE
5 - 12
DISC BRAKE CALIPERS (Continued) OPERATIONWhen the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal (Fig. 16).
Fig.16BrakeCaliperOperation
1 - CALIPER 2 - PISTON 3 - PISTON BORE 4 - SEAL 5 - INBOARD SHOE 6 - OUTBOARD SHOE
Fluid pressure applied to the piston is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the pis- ton bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor.
In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamp- ing action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop.
Application and release of the brake pedal gener- ates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and pis- ton return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The rea- sons for this are to keep road debris from getting
DR
between the rotor and lining and in wiping the rotor surface clear each revolution.
The caliper piston seal controls the amount of pis- ton extension needed to compensate for normal lining wear.
During brake application, the seal is deflected out- ward by fluid pressure and piston movement (Fig. 17). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston.
The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the pis- ton and inboard brake pad.
Fig.17LiningWearCompensationByPistonSeal 1 - PISTON 2 - CYLINDER BORE 3 - PISTON SEAL BRAKE PRESSURE OFF 4 - CALIPER HOUSING 5 - DUST BOOT 6 - PISTON SEAL BRAKE PRESSURE ON
REMOVAL
REMOVAL - REAR
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle. (3) Remove the wheel and tire assembly. (4) Drain small amount of fluid from master cylin-
der brake reservoir with suction gun.
(5) Remove the brake hose banjo bolt if replacing
(6) Remove the caliper mounting slide pin bolts
caliper (Fig. 18).
(Fig. 18).
(7) Remove the caliper from vehicle.
REMOVAL - FRONT
CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely.
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
DR DISC BRAKE CALIPERS (Continued)
BRAKES - BASE
5 - 13
Fig.18DISCBRAKECALIPER-REAR
Fig.208LUGROTOR&CALIPERASSEMBLY
1 - CALIPER ADAPTER 2 - CALIPER ADAPTER MOUNTING BOLTS 3 - CALIPER SLIDE BOLTS 4 - BRAKE HOSE 5 - CABLE 6 - CALIPER 7 - ROTOR 8 - ANTI-RATTLE CLIPS
(2) Raise and support the vehicle. (3) Remove the tire and wheel assembly. (4) Compress the disc brake caliper. (5) Remove the banjo bolt and discard the copper
(6) Remove the caliper slide pin bolts. (7) Remove the disc brake caliper (Fig. 19) or (Fig.
washer.
20).
1 - ROTOR 2 - CALIPER ADAPTER 3 - ANTI-RATTLE CLIPS 4 - BRAKE HOSE WITH BANJO BOLT 5 - DISC BRAKE CALIPER 6 - OUTBOARD BRAKE PAD
DISASSEMBLY
(1) Drain the brake fluid from caliper. (2) C-clamp a block of wood over one piston (Fig.
21).
Fig.19DISCBRAKECALIPER-FRONT
1 - STEERING KNUCKLE 2 - DISC BRAKE CALIPER 3 - CALIPER MOUNTING ADAPTER 4 - DISC BRAKE ROTOR
Fig.21C-ClampOnePiston
1 - BLOCK OF WOOD 2 - C-CLAMP 3 - CALIPER
(3) Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal (Fig. 22).
(4) To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.
BRAKES - BASE
5 - 14
DISC BRAKE CALIPERS (Continued)DR
Fig.23PistonDustBootRemoval
1 - CALIPER 2 - DUST BOOT
Fig.22ProtectCaliperPiston
1 - CALIPER 2 - PADDED BLOCK OF WOOD 3 - C-CLAMP
CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS- TON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY.
(5) Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore.
(6) Move the padded piece of wood in front of the
other piston.
(7) Remove the second piston using the same pro-
cedure with short bursts of low pressure air.
(8) Remove piston dust boots with a suitable pry
tool (Fig. 23).
(9) Remove piston seals from caliper (Fig. 24).
CAUTION: Do not scratch piston bore while remov- ing the seals.
(10) Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper (Fig. 25).
(11) Remove caliper bleed screw.
