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INSPECTION
The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing.
Fig.24PistonSeal
1 - CALIPER 2 - PISTON BORE 3 - PISTON SEAL
CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never inter- change phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
The bore can be lightly polished with a brake hone to remove very minor surface imperfections (Fig. 26). The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).
DR DISC BRAKE CALIPERS (Continued)
BRAKES - BASE
5 - 15
Fig.25BushingsAndBootSeals
1 - CALIPER 2 - BUSHING 3 - BOOT SEAL
Fig.27PistonSeal
1 - CALIPER 2 - PISTON BORE 3 - PISTON SEAL
(4) Stretch boot rearward to straighten boot folds,
then move boot forward until folds snap into place.
(5) Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle (Fig. 28).
Fig.26PolishingPistonBore
1 - HONE 2 - CALIPER 3 - PISTON BORE
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali- per seals. Insure assembly area is clean and dry.
(1) Lubricate caliper pistons, piston seals and pis-
ton bores with clean, fresh brake fluid.
(2) Install new piston seals into caliper bores (Fig.
27).
NOTE: Verify seal is fully seated and not twisted.
(3) Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston.
Fig.28CaliperPistonInstallation
1 - CALIPER 2 - DUST BOOT 3 - PISTON
C-4171 and Installer:
(6) Seat dust boot in caliper (Fig. 29) with Handle † HD 56 mm caliper: Installer C-4340
† LD 54 mm caliper: Installer C-3716-A (7) Install the second piston and dust boot. (8) Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corningt 807 grease only.BRAKES - BASE
5 - 16
DISC BRAKE CALIPERS (Continued)DR
INSTALLATION - FRONT
NOTE: Install a new copper washers on the banjo bolt when installing
(1) Install the disc brake caliper (Fig. 19) or (Fig.
20).
CAUTION: Verify brake hose is not kinked before tightening fitting bolt.
twisted or
Fig.29SeatingDustBoot
1 - HANDLE 2 - CALIPER 3 - DUST BOOT INSTALLER
CAUTION: Use of alternative grease may cause damage to the boots seals.
(9) Install the boot seals into the caliper seal bores
and center the seals in the bores.
(10) Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing.
(11) Install caliper bleed screw.
INSTALLATION
INSTALLATION - REAR
(1) Install caliper to the caliper adapter. (2) Coat the caliper mounting slide pin bolts with silicone grease. Then install and tighten the bolts to 15 N·m (11 ft. lbs.).
(3) Install the brake hose banjo bolt if removed. (4) Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 31 N·m (23
ft. lbs.).CAUTION: Verify brake hose is not kinked before tightening fitting bolt.
twisted or
(5) Remove the prop rod from the vehicle. (6) Bleed the base brake system,(Refer to 5 - BRAKES - STANDARD PROCEDURE) OR (Refer to 5 - BRAKES - STANDARD PROCEDURE).
(7) Install the wheel and tire assemblies (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE).
(8) Remove the supports and lower the vehicle. (9) Verify a firm pedal before moving the vehicle.
(2) Install the banjo bolt with new copper washers
to the caliper. Tighten to 27 N·m (20 ft. lbs.)
(3) Install the caliper slide pin bolts. tighten to 32
N·m (24 ft. lbs.)
(4) Remove the prop rod. (5) Bleed the base brake system,
BRAKES/HYDRAULIC/MECHANICAL DARD PROCEDURE).
(Refer to 5 - STAN-
(6) Install the tire and wheel assembly, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE).
(7) Lower the vehicle.
DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - REAR
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Drain a small amount of fluid from master cyl-
inder brake reservoir with a clean suction gun.
(4) Bottom the caliper pistons into the caliper by
prying the caliper over.
(5) Remove the caliper mounting bolts (Fig. 30). (6) Remove the disc brake caliper from the mount.
CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely.
(7) Remove the inboard and outboard brake pads
(8) Remove the anti-rattle clips (Fig. 30). (9) Remove the caliper adapter mounting bolts
(Fig. 30).
(Fig. 30).
REMOVAL - FRONT
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly.
DR DISC BRAKE CALIPER ADAPTER (Continued)
BRAKES - BASE
5 - 17
(2) Install the anti-rattle clips (Fig. 30). (3) Install the inboard and outboard pads (Fig. 30). (4) Install the caliper mounting bolts. (5) Install the tire and wheel assembly
INSTALLATION - FRONT
(1) Install
the caliper adapter to the steering
knuckle (Fig. 31).
(2) Install the caliper adapter mounting bolts and
tighten to 176 N·m (130 ft.lbs.) (Fig. 31).
(3) Install the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(4) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(5) Remove the support and lower the vehicle.
DISC BRAKE CALIPER ADAPTER MOUNT REMOVAL - REAR
(1) Remove wheel and tire assembly. (2) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(5) Remove the axle shaft (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(7) Remove the parking brake cable from the
brake lever.
(8) Remove the bolts attaching the support plate to
the axle and remove the support plate (Fig. 54).
(9) Remove the caliper adapter mount from the
axle housing (Fig. 32).
INSTALLATION
housing (Fig. 32).
(1) Install the caliper adapter mount on the axle
(2) Install support plate on axle flange (Fig. 55).
Tighten attaching bolts to 115 N·m (85 ft. lbs.).
(3) Install parking brake cable in the brake lever. (4) Install the park brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLA- TION). (Fig. 55).
(5) Install axle shaft, (Refer to 3 - DIFFEREN- TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE SHAFTS - INSTALLATION).
Fig.30CALIPERMOUNT
1 - DISC BRAKE PADS 2 - ANTI-RATTLE CLIPS 3 - CALIPER ADAPTER 4 - MOUNTING BOLTS
(3) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove the bolts securing the caliper adapter
to the steering knuckle (Fig. 31)
Fig.31CALIPERADAPTER
1 - CALIPER ASSEMBLY 2 - MOUNTING BOLT 3 - DISC BRAKE ROTOR
(5) Remove the caliper adapter.
INSTALLATION
INSTALLATION - REAR
(1) Install
the caliper adapter mounting bolts. Tighten the mounting bolts to 135 N·m (100 ft.lbs) (Fig. 30).
BRAKES - BASE
5 - 18
DISC BRAKE CALIPER ADAPTER MOUNT (Continued)DR
STANDARD PROCEDURE - BRAKE FLUID LEVEL
Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 33).
The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level.
Fig.32CALIPERADAPTERMOUNT-REAR
1 - CALIPER ADAPTER MOUNT 2 - AXLE TUBE 3 - MOUNTING STUDS
(6) Adjust brake shoes to drum with brake gauge (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - ADJUSTMENTS).
(7) Install the rotor (Refer to 5 - BRAKES/HY- INSTALLA-
DRAULIC/MECHANICAL/ROTORS - TION).
(8) Install
the caliper adapter
(Refer
to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - INSTALLATION).
(9) Install the caliper (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(10) Install wheel and tire assembly.
FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid sepa- rates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If brake fluid is contaminated, drain and thor- oughly flush system. Replace master cylinder, propor- tioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses.
Fig.33FLUIDLEVEL
1 - FLUID RESERVOIR 2 - MAX LEVEL MARK
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc.
DR
BRAKES - BASE
5 - 19
FLUID RESERVOIR REMOVAL
(1) Install the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the reservoir cap and siphon fluid into
a drain container (Fig. 34).
(3) Remove the electrical connector from the fluid
level switch in the reservoir (Fig. 34).
(4) Remove the reservoir mounting bolt (Fig. 34). (5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body (Fig.
34).
Fig.34FLUIDRESERVOIR
1 - MASTER CYLINDER CAP 2 - FLUID RESERVOIR 3 - FLUID LEVEL SWITCH 4 - MASTER CYLINDER 5 - MOUNTING BOLT 6 - GROMMETS
INSTALLATION
CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets cre- ating a leak problem after installation. Install the grommets using finger pressure only.
(1) Lubricate the new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets.
(2) Start the reservoir in grommets. Then rock the reservoir back and forth while pressing downward to seat it into the grommets.
(3) Install the mounting bolt for the reservoir to
the master cylinder.
reservoir level switch.
(4) Reconnect the electrical connector to the fluid
(5) Remove the prop rod from the vehicle.
(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE JUNCTION BLOCK REMOVAL
(1) Remove the brake lines from the junction block
(Fig. 35).
(2) Remove the junction block mounting bolt and remove the junction block from the bracket (Fig. 35).
Fig.35JUNCTIONBLOCK
1 - BRAKE LINES 2 - JUNCTION BLOCK
INSTALLATION
(1) Position the junction block on the bracket and install the mounting bolt. Tighten the mounting bolt to 23 N·m (210 in. lbs.) (Fig. 35).
(2) Install the brake lines into the junction block and tighten to 19-23 N·m (170-200 in. lbs.) (Fig. 35). (Refer to 5 - STAN-
(3) Bleed the base brake system,
BRAKES/HYDRAULIC/MECHANICAL DARD PROCEDURE).
MASTER CYLINDER DESCRIPTION
A two-piece master cylinder is used on all models. The cylinder body containing the primary and sec- ondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicat- ing low fluid levels. The reservoir is the only service- able component.
The fluid compartments of the nylon reservoir are fluid level equalization. interconnected to permit However, the equalization feature does not affect cir-
BRAKES - BASE
5 - 20
MASTER CYLINDER (Continued)DR
cuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic cir- cuit.
Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading.
The cylinder reservoir can be replaced when neces- sary. However, the aluminum body section of the master cylinder is not a repairable component.
NOTE: If diagnosis indicates that an internal mal- function has occurred, the aluminum body section must be replaced as an assembly.
OPERATION
The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes.
DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leak- age).
(5) Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Pro- ceed to the POWER BOOSTER VACUUM TEST.
(6) If
the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately turn off igni- tion to stop engine.(7) Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vac- uum assisted pedal applications. If vacuum assist is not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 36).
(2) Start and run engine at curb idle speed for one
minute.
check valve.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
(5) Stop engine and observe vacuum gauge. (6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or check valve is faulty.Fig.36TypicalBoosterVacuumTestConnections 1 - TEE FITTING 2 - SHORT CONNECTING HOSE 3 - CHECK VALVE 4 - CHECK VALVE HOSE 5 - CLAMP TOOL 6 - INTAKE MANIFOLD 7 - VACUUM GAUGE
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve. (2) Remove check valve and valve seal
from
booster.
(3) Use a hand operated vacuum pump for test. (4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 37).
(5) Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING
A new master cylinder should be bled before instal- lation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line.
DR MASTER CYLINDER (Continued)
BRAKES - BASE
5 - 21
NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster.
Fig.37VacuumCheckValveAndSeal
1 - BOOSTER CHECK VALVE 2 - APPLY TEST VACUUM HERE 3 - VALVE SEAL
(1) Mount master cylinder in vise. (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir (Fig. 38).
(3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid.
Fig.39MASTERCYLINDER
1 - MASTER CYLINDER RESERVOIR 2 - POWER BRAKE BOOSTER 3 - BRAKE LINES 4 - MASTER CYLINDER
REMOVAL - HYDROBOOST
(1) Remove the brake lines from the master cylin-
der (Fig. 40).
Fig.38MasterCylinderBleeding–Typical
1 - BLEEDING TUBES 2 - RESERVOIR
REMOVAL
REMOVAL - ALL EXCEPT HYDROBOOST
Fig.40HYDROBOOSTMASTERCYLINDER
1 - HYDROBOOST UNIT 2 - MASTER CYLINDER RESERVOIR 3 - MASTER CYLINDER 4 - MOUNTING NUTS
(1) Remove the brake lines from the master cylin-
(2) Disconnect the electrical connector for the low
(2) Disconnect the electrical connector for the low
(3) Remove the mounting nuts from the master
der (Fig. 39).
fluid level.
fluid level.
cylinder (Fig. 40).
(4) Remove the master cylinder.
(3) Remove the mounting nuts from the master
cylinder (Fig. 39).
(4) Remove the master cylinder.
BRAKES - BASE
5 - 22
MASTER CYLINDER (Continued)NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster.
DR
(4) Reconnect the elctrical connector for the low
fluid level switch.
(5) Fill and bleed the base brake system. (Refer to
5 - BRAKES - STANDARD PROCEDURE).
INSTALLATION
INSTALLATION - HYDROBOOST
INSTALLATION - ALL EXCEPT HYDROBOOST
NOTE: If master cylinder is replaced bleed cylinder before installation.
NOTE: If master cylinder is replaced bleed cylinder before installation.
NOTE: Make sure the output rod of the brake booster is in position before mounting of the mas- ter cylinder “This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation”. Proper position is obtained when the output rod is centered perpen- dicular to the master cylinder mounting hole (Fig. 41).
Fig.41OUTPUTRODORIENTATION
1 - MASTER CYLINDER RESERVOIR 2 - CHECK VALVE 3 - BOOSTER 4 - BOOSTER MOUNTING STUDS 5 - INPUT ROD 6 - OUTPUT ROD 7 - MASTER CYLINDER MOUNTING STUDS 8 - MASTER CYLINDER 9- ELECTRICAL CONNECTOR
NOTE: Before installing the master cylinder, pump the brake pedal several times with the engine off to remove vacuum from the booster.
(1) Install
the master cylinder on the booster
mounting studs.
N·m (221 in. lbs.)
(170 in. lbs.)
(2) Install new mounting nuts and tighten to 25
(3) Install the brake lines and tighten to 19 N·m
NOTE: Make sure the output rod of the brake booster is in position before mounting of the mas- ter cylinder “This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation”. Proper position is obtained when the output rod is centered perpen- dicular to the master cylinder mounting hole (Fig. 41).
(1) Install
the master cylinder on the booster
mounting studs (Fig. 40).
(2) Install new mounting nuts and tighten to 25
N·m (221 in. lbs.)
(170 in. lbs.)
fluid level switch.
(3) Install the brake lines and tighten to 19 N·m
(4) Reconnect the elctrical connector for the low
(5) Fill and bleed the base brake system. (Refer to
5 - BRAKES - STANDARD PROCEDURE).
PEDAL DESCRIPTION
NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket.
A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot shaft pin and bushings. If the bushings become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are not serviceable components (Fig. 42).
OPERATION
The brake pedal is attached to the booster push rod. When the pedal the primary booster push rod is depressed which move the booster secondary rod. The booster secondary rod depress the master cylinder piston.
is depressed,
DR PEDAL (Continued)
BRAKES - BASE
5 - 23
Fig.42BRAKEPEDAL
Fig.43PEDAL/CABLE
1 - CABLE 2 - BRAKE PEDAL ASSEMBLY
1 - CLIP 2 - BUSHINGS 3 - PIVOT SHAFT PIN 4 - PEDAL ASSEMBLY ADJUSTABLE PEDAL SHOWN NON ADJUSTABLE PEDAL IS SIMILIAR 5 - PAD
REMOVAL
NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket.
(1) Disconnect the negative battery cable. (2) Remove the steering column opening cover(Re- fer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL).
(3) Remove the brake lamp switch and discard(Re- fer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTE- RIOR/BRAKE LAMP SWITCH - REMOVAL).
(4) On vehicles equipped with adjustable ped- als. Disconnect the adjuster cable to the pedal (Fig. 43).
(5) Remove the steering column (Refer to 19 -
STEERING/COLUMN - REMOVAL).
(6) Remove the brake booster (Fig. 44)(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - REMOVAL).
(7) Disconnect the electrical connectors. (8) Remove the module mounting bolts. (9) Disconnect the accelerator pedal cable. (10) Remove the pedal assembly mounting nuts/
fasteners (Fig. 44).
INSTALLATION
(1) Install the pedal assembly to the vehicle (Fig.
44).
(2) Install the mounting bolts (Fig. 44) and tighten
to 28 N·m (21 ft. lbs.).
(3) Reconnect the accelerator cable to the pedal.
Fig.44PEDALASSEMBLY(ADJUSTABLEPEDALS
SHOWN)
1 - ADJUSTABLE PEDAL MOTOR 2 - PEDAL ASSEMBLY BRACKET 3 - MOUNTING NUT 4 - BRAKE & ACCELERATOR PEDAL 5 - BRAKE BOOSTER MOUNTING STUDS
(4) Install the module mounting bolts and tighten
to 38 N·m (28 ft. lbs.).
(5) Reconnect the electrical connectors. (6) Install the brake booster (Refer to 5 - BRAKES/ BRAKE
HYDRAULIC/MECHANICAL/POWER BOOSTER - INSTALLATION).
(7) Install
the steering column (Refer to 19 -
STEERING/COLUMN - INSTALLATION).
(8) Install a new brake lamp switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL).
(9) On vehicles equipped with adjustable brake pedal.Reconnect the electrical connector to the motor and the adjuster cable at the pedal.
BRAKES - BASE
5 - 24
PEDAL (Continued)DR
(10) Install
the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION).
(11) Reconnect the negative battery cable.
ADJUSTABLE PEDAL MOTOR DESCRIPTION
The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonom- ics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal posi- tions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals.
Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (Fig. 45). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable.
The accelerator pedal is moved at the same time
and the same distance as the brake pedal.
Neither the pedal drive motor (Fig. 45) nor drive mechanism are subject to the mechanical stress of brake or accelerator application.
adjusted up to 3 in. (75 mm)
† SYSTEM FEATURES: † Range of Adjustment: The pedals may be † Pedal Adjustment Speed: 0.5 in./sec (12.5
mm/sec) † Pedal Adjustment Inhibitors: Pedal adjust- ment is inhibited when the vehicle is in reverse or when cruise control is activated.REMOVAL
(1) Disconnect the negative battery cable. (2) Remove the kneeblocker (Refer to 23 - BODY/ COLUMN
PANEL/STEERING
INSTRUMENT OPENING COVER - REMOVAL).
(3) Remove the brake light switch and discard (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(4) Disconnect the adjustable pedal cables from the
brake and accelerator pedals.
(5) Disconnect the electrical connector. (6) Unclip the cable fasteners to the support.
Fig.45ADJUSTABLEPEDALMOTOR
1 - ADJUSTABLE PEDAL MOTOR 2 - CABLES 3 - ELECTRICAL CONNECTOR
(7) Remove the one mounting bolt for the adjust-
able pedal motor (Fig. 46).
(8) Remove the adjustable pedal motor with the
cables.
NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed.
Fig.46ADJUSTABLEPEDALMOTOR
1 - ADJUSTABLE PEDAL MOTOR 2 - MOUNTING BOLT
INSTALLATION
NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed.
(1) Install the adjustable pedal motor with the
cables.
DR ADJUSTABLE PEDAL MOTOR (Continued)
BRAKES - BASE
5 - 25
(2) Install the one mounting bolt for the adjustable
pedal motor (Fig. 46).
(3) Clip the cable fasteners to the support. (4) Reconnect the electrical connector. (5) Reconnect the adjustable pedal cables to the
brake and accelerator pedals.
(6) Install the new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL).
(7) Install the kneeblocker (Refer to 23 - BODY/IN- STRUMENT PANEL/STEERING COLUMN OPEN- ING COVER - INSTALLATION).
(8) Reconnect the negative battery cable. (9) Check for proper operation of the pedals.
POWER BRAKE BOOSTER DESCRIPTION
All models use a tandem diaphragm, power brake
booster.
NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred.
OPERATION
The booster unit consists of a single housing divided into two by a tandem diaphragm. The outer edge of the diaphragm is secured to the housing. The booster push rod, which connects the booster to the brake pedal and master cylinder, is attached to the center of the diaphragm. A check valve is used in the booster outlet connected to the engine intake mani- fold. Power assist is generated by utilizing a combi- nation of vacuum and atmospheric pressure to boost brake assist.
REMOVAL
(1) Remove master cylinder. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/MASTER CYLINDER - REMOVAL).
(2) Disconnect vacuum line at booster. (3) Remove clip securing booster push rod to brake pedal (Refer to 5 - BRAKES/HYDRAULIC/MECHAN- ICAL/PEDAL - REMOVAL). (Fig. 47).
(4) Remove the nuts from the booster mounting
(5) Remove the booster and gasket from front cowl
studs (Fig. 47).
panel.
INSTALLATION
(1) Guide the booster studs into the cowl panel
holes and seat the booster on the panel (Fig. 47).
Fig.47POWERBRAKEBOOSTER
1 - MOUNTING NUT 2 - POWER BRAKE BOOSTER
(2) Install and tighten new booster attaching nuts
to 28 N·m (250 in. lbs.).
install clip (Fig. 47).
(3) Install the booster push rod on brake pedal and
(4) Install the booster check valve if removed and
connect the vacuum hose to the check valve.
(5) Install
the master cylinder.
(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - INSTALLATION).
(6) Fill and bleed the brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
HYDRO-BOOST BRAKE BOOSTER DIAGNOSIS AND TESTING - HYDRAULIC BOOSTER
The hydraulic booster uses hydraulic pressure from the power steering pump. Before diagnosing a booster problem, first verify the power steering pump is operating properly. Perform the following checks.
† Check the power steering fluid level. † Check the brake fluid level. † Check all power steering hoses and lines for † Check power steering pump pressure.
leaks and restrictions.
NOISES
The hydraulic booster unit will produce certain characteristic booster noises. The noises may occur when the brake pedal is used in a manner not asso- ciated with normal braking or driving habits.
BRAKES - BASE
5 - 26
HYDRO-BOOST BRAKE BOOSTER (Continued)DR
HISSING
A hissing noise may be noticed when above normal brake pedal pressure is applied, 40 lbs. or above. The noise will be more noticeable if the vehicle is not moving. The noise will increase with the brake pedal pressure and an increase of system operating temper- ature.
CLUNK-CHATTER-CLICKING
A clunk-chatter-clicking may be noticed when the brake pedal is released quickly, after above normal brake pedal pressure is applied 50-100 lbs..
BOOSTER FUNCTION TEST
With the engine off depress the brake pedal several times to discharge the accumulator. Then depress the brake pedal using 40 lbs. of force and start the engine. The brake pedal should fall and then push back against your foot. This indicates the booster is operating properly.
ACCUMULATOR LEAKDOWN
(1) Start the engine, apply the brakes and turn the steering wheel from lock to lock. This will ensure the accumulator is charged. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two power assisted brake applica- tion with the engine off. If the system does not retain a charge the booster must be replaced.
(2) With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced.
SEAL LEAKAGE
If the booster leaks from any of the seals the
booster assembly must be replaced (Fig. 48).
front of booster.
end of the booster.
† INPUT ROD SEAL: Fluid leakage from rear † PISTON SEAL: Fluid leakage from vent at † HOUSING SEAL: Fluid leakage between hous- † SPOOL VALVE SEAL: Fluid leakage near † RETURN PORT FITTING SEAL: Fluid leak-
ing and housing cover.
spool plug.
age from port fitting.
Fig.48HydraulicBoosterSeals
1 - PUMP 2 - GEAR 3 - INPUT SEAL 4 - HOUSING SEAL 5 - ACCUMULATOR SEAL 6 - PISTON SEAL 7 - SPOOL PLUG SEAL 8 - RETURN
HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
Slow Brake Pedal Return
1. Excessive seal friction in booster.
1. Replace booster.
2. Faulty spool valve action. 3. Restriction in booster return hose. 4. Damaged input rod.
2. Replace booster. 3. Replace hose. 4. Replace booster.
Excessive Brake Pedal Effort.
1. Internal or external seal leakage. 2. Faulty steering pump.
1. Replace booster. 2. Replace pump.
DR HYDRO-BOOST BRAKE BOOSTER (Continued)
BRAKES - BASE
5 - 27
CONDITION
POSSIBLE CAUSES
CORRECTION
Brakes Self Apply
1. Dump valve faulty.
1. Replace booster.
2. Contamination in hydraulic system. 3. Restriction in booster return hose.
2. Flush hydraulic system and replace booster. 3. Replace hose.
Booster Chatter, Pedal Vibration
Grabbing Brakes
1. Slipping pump belt.
1. Replace power steering belt.
2. Low pump fluid level.
2. Fill pump and check for leaks.
1. Low pump flow. 2. Faulty spool valve action.
1. Test and repair/replace pump. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air.
(1) Fill power steering pump reservoir. (2) Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING.
(3) Check fluid level and add if necessary. (4) Connect fuel shutdown relay and start the
(5) Turn the steering wheel slowly from lock to
engine.
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis- sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster.
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal.
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster.
Fig.49HYDRO-BOOSTUNIT
1 - INLET HOSE 2 - HYDRO-BOOST UNIT 3 - MASTER CYLINDER UNIT 4 - RETURN HOSE 5 - OUTLET HOSE
INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N·m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
(1) With engine off depress the brake pedal 5
onto the brake pedal.
times to discharge the accumulator.
(2) Remove brake lines from master cylinder. (3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder. (6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 49).
(3) Install the master cylinder on the mounting studs. and tighten the mounting nuts to 23 N·m (17
ft. lbs.).(4) Install the brake lines to the master cylinder
and tighten to 19-200 N·m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N·m (17 ft. lbs.).
BRAKES - BASE
5 - 28
HYDRO-BOOST BRAKE BOOSTER (Continued)DR
(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N·m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings to insure they are in good condition before installa- tion. Replace o-rings if necessary.
(9) Install the return hose to the booster. (Refer (10) Bleed base brake system,
BRAKES/HYDRAULIC/MECHANICAL DARD PROCEDURE).
to 5 - STAN-
(11) Fill
the power steering pump with fluid, (Refer to 19 - STEERING/PUMP - STANDARD PRO- CEDURE).
Fig.50REARROTOR
1 - ROTOR 2 - CALIPER ADAPTER 3 - CALIPER
CAUTION: MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
(12) Bleed the hydraulic booster (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - STANDARD PROCEDURE).
ROTORS
REMOVAL
REMOVAL - REAR
(1) Raise and support the vehicle (2) Remove the tire and wheel assembly. (3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
the
caliper
(4) Remove
(Fig. 50).(Refer to 5 - BRAKES/HYDRAULIC/MECHANI- CAL/DISC REMOVAL)
ADAPTER
CALIPER
BRAKE
adapter
bolts
(5) Remove the retianing clips and rotor assembly
(Fig. 50).
REMOVAL - FRONT
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the caliper from the steering knuckle, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPERS - REMOVAL) and remove caliper adapter assembly (Fig. 51).
NOTE: Do not allow brake hose to support caliper adapter assembly.
Fig.51CaliperAdapterAssembly
1 - KNUCKLE 2 - CALIPER 3 - ROTOR
(4) Remove the rotor from the hub/bearing wheel
studs (Fig. 52) or (Fig. 53).
INSTALLATION
INSTALLATION - REAR
(1) Install the rotor to the axleshaft (Fig. 50).
DR ROTORS (Continued)
BRAKES - BASE
5 - 29
INSTALLATION - FRONT
(1) On models with all-wheel antilock system (ABS), check condition of tone wheel on hub/bearing. If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately).
(2) Install the rotor onto the hub/bearing wheel
studs.
(3) Install the caliper adapter assembly,(Refer to 5
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION) and tighten adapter bolts to:(4) Install the wheel and tire assembly, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE) and lower the vehicle.
(5) Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle.
SUPPORT PLATE REMOVAL
(1) Remove wheel and tire assembly. (2) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(5) Remove the axle shaft (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(7) Remove the parking brake cable from the
brake lever.
(8) Remove the bolts attaching the support plate to
the axle and remove the support plate (Fig. 54).
Fig.52FRONTROTOR
1 - ROTOR 2 - HUB/BEARING
Fig.538LUGROTORASSEMBLY
1 - SPRING 2 - SHOCK 3 - UPPER AND LOWER SUSPENSION ARMS 4 - DISC BRAKE CALIPER 5 - DISC BRAKE CALIPER ADAPTER 6 - ROTOR
(2) Install the caliper adapter (Fig. 50) (Refer to 5
BRAKES/HYDRAULIC/MECHANICAL/DISCBRAKE CALIPER ADAPTER - INSTALLATION).
(3) Install the caliper adapter bolts (Fig. 50) and
tighten the mounting bolts to 135 N·m (100 ft.lbs).
(4) Install the disc brake caliper,
(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(6) Lower the vehicle.
INSTALLATION
(1) Install support plate on axle flange (Fig. 55).
Tighten attaching bolts to 115 N·m (85 ft. lbs.).
(2) Install parking brake cable in the brake lever. (3) Install the park brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLA- TION). (Fig. 55).
(4) Install axle shaft, (Refer to 3 - DIFFEREN- TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE SHAFTS - INSTALLATION).
(5) Adjust brake shoes to drum with brake gauge (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - ADJUSTMENTS).
BRAKES - BASE
5 - 30
SUPPORT PLATE (Continued)DR
PARKING BRAKE DESCRIPTION
The parking brakes are operated by a system of cables and levers attached to a primary and second- ary shoe positioned within the drum section of the rotor.
The drum-in-hat design utilizes an independent set
of shoes to park the vehicle (Fig. 56).
Fig.54SUPPORTPLATE
1 - SUPPORT PLATE 2 - MOUNTING STUDS
(6) Install the rotor (Refer to 5 - BRAKES/HY- INSTALLA-
DRAULIC/MECHANICAL/ROTORS - TION).
(7) Install
the caliper adapter
(Refer
to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - INSTALLATION).
(8) Install the caliper (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(9) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).Fig.55SUPPORTPLATEWITHBRAKESMOUNTED 1 - SUPPORT PLATE 2 - MOUNTING NUTS
Fig.56SUPPORTPLATEWITHBRAKESMOUNTED 1 - SUPPORT PLATE 2 - MOUNTING NUTS
OPERATION
To apply the parking brake the pedal is depressed. This creates tension in the cable which pulls forward on the park brake lever. The lever pushes the park brake shoes outward and into contact with the drum section of the rotor. The contact of shoe to rotor parks the vehicle.
A torsion locking mechanism is used to hold the pedal in an applied position. Parking brake release is accomplished by the hand release.
A parking brake switch is mounted on the parking brake lever and is actuated by movement of the lever. The switch, which is in circuit with the red warning light in the dash, will illuminate the warn- ing light whenever the parking brake is applied.
Parking brake adjustment is controlled by a cable tensioner mechanism. The cable tensioner, once adjusted at the factory, should not need further adjustment under normal circumstances. Adjustment may be required if a new tensioner, or cables are installed, or disconnected.
DR
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE CABLE
BRAKES - BASE
5 - 31
(1) Raise and support vehicle. (2) Lockout the parking brake cable (Fig. 58). (3) Loosen adjusting nut to create slack in front
(4) Remove the front cable from the cable connec-
cable.
tor.
(5) Compress
cable
end fitting at underbody
bracket and remove the cable from the bracket.
(6) Lower vehicle. (7) Push ball end of cable out of pedal clevis with
small screwdriver.
(8) Compress cable end fitting at the pedal bracket
and remove the cable (Fig. 57).
Fig.58LOCKOUTPARKINGCABLE
1 - LOCKING PLIERS 2 - PARKING BRAKE CABLE
(5) Compress tabs on cable end fitting on the rear park brake cable to the frame mount bracket. Then pull the cable through the bracket.
(6) Disengage the park brake cable from behind
the rotor assembly. (Fig. 59).
Fig.57ParkingBrakePedal
Fig.59DISENGAGEMENTOFCABLE
1 - PARK BRAKE PEDAL 2 - FRONT CABLE
1 - LEVER 2 - CABLE END
(9) Remove the left cowl trim and sill plate. (10) Pull up the carpet and remove the cable from
the body clip.
(7) Compress cable tabs on each cable end fitting
at the brake cable support plate.
(8) Remove the cables from the brake cable sup-
(11) Pull up on the cable and remove the cable
port plates.
with the body grommet.
REMOVAL - REAR PARK BRAKE CABLE
(1) Raise and support the vehicle. (2) Lockout the parking brake cable (Fig. 58). (3) Loosen cable adjuster nut. (4) Remove the rear park brake cable from the
intermediate park brake cable.
REMOVAL - RIGHT REAR CABLE (1) Raise and support the vehicle. (2) Lockout the parking brake cable (Fig. 58). (3) Loosen the brake cable at the equalizer and
adjuster nut.
(4) Remove the right cable from the front cable. (5) Remove the right cable from the equalizer.
5 - 32
BRAKES - BASE CABLES (Continued)DR
(6) Remove the cable from the frame bracket. (7) Remove the cable from the axle bracket. (8) Remove the cable bracket
from the shock
(9) Remove the brake cable from the brake lever.
bracket.
(Fig. 60)
Fig.60CABLEMOUNT
1 - SUPPORT PLAT 2 - CABLE MOUNT 3 - PARK BRAKE LEVER 4 - CABLE
REMOVAL - LEFT REAR CABLE (1) Raise and support the vehicle. (2) Lockout the parking brake cable (Fig. 58). (3) Loosen the brake cable at the equalizer and
adjuster nut.
bracket.
(Fig. 61)
(4) Remove the left brake cable from the equalizer. (5) Remove the brake cable from the frame
(6) Remove the brake cable from the brake lever.
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE CABLE
(1) From inside the vehicle, insert the cable end
fitting into the hole in the pedal assembly.
(2) Seat the cable retainer in the pedal assembly. (3) Engage the cable ball end in clevis on the pedal
assembly.
(4) Route the cable through the floorpan and
install the body grommet.
(5) Place the carpet down and install the left cowl
62)
trim and sill plate.
(6) Raise and support the vehicle. (7) Route the cable through the underbody bracket
and seat the cable end fitting in the bracket.
Fig.61REARDISCBRAKE
1 - DISC BRAKE CALIPER 2 - DISC BRAKE ROTOR 3 - DUST SHIELD 4 - REAR PARKING BRAKE CABLE 5 - DISC BRAKE CALIPER MOUNTING BOLTS
(8) Connect the cable to the cable connector. (9) Perform the park brake adjustment procedure, (Refer to 5 - BRAKES/PARKING BRAKE/CABLE TENSIONER - ADJUSTMENTS).
(10) Lower the vehicle.
INSTALLATION - REAR PARK BRAKE CABLE
(1) Push each cable end through the brake cable support plate hole until the cable end fitting tabs lock into place.
NOTE: Pull on the cable to ensure it is locked into place.
(2) Push the cable through the frame bracket. (3) Lock the left cable end fitting tabs into the
frame bracket hole.
(4) Install the rear cables into the tensioner rod
behind the rear of the brake assembly.
(5) Install the cable to the intermediate cable con-
nector.
(6) Release and remove the lock out device. (7) Perform the park brake adjustment procedure, (Refer to 5 - BRAKES/PARKING BRAKE/CABLE TENSIONER - ADJUSTMENTS).
(8) Remove the supports and lower the vehicle.
INSTALLATION - RIGHT REAR CABLE
(1) Install the brake cable to the brake lever. (Fig.
(2) Install the cable bracket to the shock bracket. (3) Install the cable to the axle bracket. (4) Install the cable to the frame bracket. (5) Install the right cable to the equalizer.
DR CABLES (Continued)
(6) Install the right cable to the front cable. (7) Adjust the brake cable at the equalizer and
using the adjuster nut.
BRAKES - BASE
5 - 33
Fig.63LOCKOUTPARKINGCABLE
1 - LOCKING PLIERS 2 - PARKING BRAKE CABLE
Fig.62PARKINGBRAKECABLE
1 - SUPPORT PLAT 2 - CABLE 3 - LEVER
INSTALLATION - LEFT REAR CABLE
(1) Install the brake cable to the brake lever (Fig.
(2) Install the brake cable to the frame bracket. (3) Install the left brake cable to the equalizer. (4) Adjust the brake cable at the equalizer and
61).
adjuster nut.
SHOES REMOVAL
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Remove the disc brake caliper,(Refer to 5 -
(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove the disc brake rotor,
BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL).
(5) Lockout the parking brake cable (Fig. 63). (6) Disengage the park brake cable from behind the rotor assembly to allow easier disassembly of the park brake shoes (Fig. 64).
(7) Remove the axleshaft (Fig. 65) (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/ AXLE SHAFTS - REMOVAL).
(8) Disassemble the rear park brake shoes (Fig.
56).
Fig.64DISENGAGEMENTOFCABLE
1 - LEVER 2 - CABLE END
CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper.
INSPECTION - REAR DRUM IN HAT BRAKE
As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 in.) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 in.).
Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be
BRAKES - BASE
5 - 34
SHOES (Continued)DR
Fig.65AXLESHAFT
1 - AXLE SHAFT 2 - SUPPORT PLATE 3 - CALIPER 4 - PARK BRAKE SHOE ASSEMBLY
replaced and the drum checked for runout or taper (Fig. 66).
Inspect the adjuster screw assembly. Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded (Fig. 66).
Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Over- heating will distort and weaken the springs.
Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted (Fig. 66).
INSTALLATION
NOTE: On a new vehicle or after parking brake lin- ing replacement, it is recommended that the park- ing brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal.
(1) Reassemble the rear park brake shoes (Fig.
56).
(2) Install the axleshaft (Fig. 65) (Refer to 3 - DIF- FERENTIAL & DRIVELINE/REAR AXLE - 9 1/4/ AXLE SHAFTS - INSTALLATION).
(3) Install the park brake cable to the lever behind
the support plate.
(4) Unlock the park brake cable. (5) Install
the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION).
Fig.66PARKBRAKESHOES
(6) Install the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(7) Adjust the rear brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - ADJUST- MENTS).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(9) Lower the vehicle.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
the park brake pedal
CAUTION: Before adjusting the park brake shoes be sure that is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted.
(1) Raise vehicle. (2) Remove tire and wheel. (3) Remove disc brake caliper from caliper adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from the axleshaft (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL).
BRAKES - BASE
5 - 35
DR SHOES (Continued)
NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum.
(5) Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, accurately measure the inside diam- eter of the park brake drum portion of the rotor (Fig. 67).
Fig.69SettingGaugeToParkBrakeShoe
Measurement
1 - RULER 2 - SPECIAL TOOL C-3919
Fig.67MeasuringParkBrakeDrumDiameter
(6) Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diam- eter of the park brake drum from the special tool (Fig. 68).
Fig.68ReadingParkBrakeDrumDiameter
1 - SPECIAL TOOL C-3919
2 - RULER(7) Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement (Fig. 69).
(8) Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes.
(9) Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on the axleshaft (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION).(12) Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum.
(13) Install disc brake caliper on caliper adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPERS - INSTALLATION).
(14) Install wheel and tire. (15) Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 N·m (95 ft. lbs.).
(16) Lower vehicle. (17) Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables.
CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle.
BRAKES - BASE
5 - 36
SHOES (Continued)NOTE: On a new vehicle or after parking brake lin- ing replacement, it is recommended that the park- ing brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle’s brake system.
ADJUSTMENT - WITH ADJUSTING TOOL
Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is per- formed with the complete brake assembly installed on the backing plate.
(1) Be sure parking brake lever is fully released. (2) Raise vehicle so rear wheels can be rotated
freely.
support plates.
(3) Remove plug from each access hole in brake
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool
access hole and engage tool screw star wheel (Fig. 70).
through support plate in teeth of adjusting
Fig.70BrakeAdjustment
1 - STAR WHEEL 2 - LEVER 3 - BRAKE SHOE WEB 4 - SCREWDRIVER 5 - ADJUSTING TOOL 6 - ADJUSTER SPRING
(6) Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated.
(7) Push and hold adjuster lever away from star
wheel with thin screwdriver.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.
DR
(9) Repeat adjustment at opposite wheel. Be sure
adjustment is equal at both wheels.
(10) Install support plate access hole plugs. (11) Adjust parking brake cable and lower vehicle. (12) Depress park brake pedal and make sure park
brakes hold the vehicle staionary. (13) Release park brake pedal.
PEDAL REMOVAL
(1) Release the parking brake. (2) Raise the vehicle. (3) Loosen the cable tensioner nut at the equalizer
to create slack in the front cable.
(4) Lower the vehicle. (5) Remove the knee bolster, (Refer to 23 - BODY/ COLUMN
PANEL/STEERING
INSTRUMENT OPENING COVER - REMOVAL).
(6) Disconnect
the brake lamp wire from the
switch on the pedal assembly.
(7) Roll the carpet back,
loosen the front cable
grommet from the floorpan and the cable retainer.
(8) Disengage the release rod (Fig. 71) from the
arm on the pedal assembly.
(9) Remove the bolts/nuts from the pedal assembly
and remove the assembly.
Fig.71PARKINGBRAKEPEDAL
1 - RELEASE ROD 2 - PEDAL ASSEMBLY
INSTALLATION
(1) Position the replacement pedal assembly on the
dash and cowl.
ft. lbs.) (Fig. 72).
assembly.
