Chrysler New Yorker. Manual — part 26
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.
RED BRAKE WARNING LAMP TEST
For diagnosis of specific problems with the red
brake warning lamp system, refer to Brake System
Diagnostics Chart 2, located in the Diagnosis And
Testing section in this group of the service manual.
STOP LAMP SWITCH
The required procedure for testing the stop lamp
switch is covered in Group 8H Vehicle Speed Control
System in this service manual. The electrical circuit
for stop lamps is covered in Group 8W Rear Lighting
in this service manual.
REAR WHEEL HUB AND BEARING
The rear hub and bearing assembly is designed for
the life of the vehicle and should require no mainte-
nance. The following procedure may be used for eval-
uation of bearing condition.
With wheel and brake drum removed, rotate
flanged outer ring of hub. Excessive roughness, lat-
eral play or resistance to rotation may indicate dirt
intrusion or bearing failure. If the rear wheel bear-
ings exhibit these conditions during inspection, the
hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive
grease loss may also require bearing replacement.
Moderate grease loss from bearing is considered nor-
mal and should not require replacement of the hub
and bearing assembly.
SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL
Check master cylinder reservoir brake fluid level a
minimum of twice a year.
The master cylinder brake fluid reservoir used on
this vehicle includes a brake fluid level sensor. The
brake fluid level sensor location is in the body of the
brake fluid reservoir (Fig. 18). In the event of low
brake fluid level in the brake fluid reservoir, the
RED brake warning light in the instrument panel
will turn on.
Master cylinder fluid reservoirs on both standard
and antilock brake systems, are marked with a
FULL fill line indicating the fluid reservoirs proper
fluid level (Fig. 18).
NOTE:
When filling brake fluid reservoir, use only
Mopar
T
brake fluid or an equivalent stored in a
tightly sealed container. Brake fluid must conform
to DOT 3, specifications. Do not use brake fluid
with a lower boiling point then DOT 3, as brake fail-
ure could result during prolonged hard braking. Do
not use petroleum-based fluid because seal damage
in the brake system will result.
If necessary, add brake fluid to reservoir, bringing
brake fluid level to the FULL fill line shown on fluid
reservoir (Fig. 18).
BRAKE BLEEDING
NOTE: To
bleed
this
vehicles
antilock
brakes
hydraulic system, see the antilock brake system
service procedures in this group of the service
manual. It describes in detail the required proce-
dure which needs to be followed when bleeding the
antilock brake system.
CAUTION: Before removing the master cylinder
cover, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder.
PRESSURE BLEEDING
CAUTION: Use bleeder tank Special Tool C-3496-B
or equivalent, with Adapter, Special Tool 8224 (Fig.
19), to pressurize the brake hydraulic system for
bleeding.
Follow pressure bleeder manufacturer’s instruc-
tions, for use of pressure bleeding equipment.
When bleeding the brake system. Some air may be
trapped in the brake lines or valves far upstream. As
much as ten feet from the bleeder screw (Fig. 20).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes. This
will ensure all the air is bled from the brakes
hydraulic system.
Fig. 18 Master Cylinder Fluid Level
5 - 18
BRAKES
300M
DIAGNOSIS AND TESTING (Continued)
(1) Remove rubber dust caps from all 4 bleeder
screws.
(2) Attach a clear hose to the bleeder screw at one
wheel and feed the hose into a clear jar containing
fresh brake fluid (Fig. 21).
CAUTION:
Just cracking the bleeder screw often
restricts fluid flow, and a slow weak fluid discharge
will NOT get all the air out.
(3) Open bleeder screw (Fig. 21) on caliper assem-
bly or wheel cylinder, at least one full turn or more
to obtain an adequate flow of brake fluid.
(4) After 4 to 8 ounces of brake fluid has been bled
through an individual wheel’s brake hydraulic sys-
tem. And an air-free flow (no bubbles) is maintained
in the clear plastic hose and jar, this will indicate a
good bleed of this individual hydraulic circuit.
(5) Repeat the procedure at all the other remain-
ing bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been improved.
Enough fluid has not passed through the system to
expel all the trapped air. Be sure to monitor the fluid
level in the pressure bleeder. It must stay at the
proper level so air will not be allowed to reenter the
brake system through the master cylinder.
(6) Replace all 4 bleeder screw rubber dust caps.
BLEEDING WITHOUT A PRESSURE BLEEDER
If a pressure bleeder is not available. A good brake
fluid flow can be obtained by manual bleeding of the
brake hydraulic system, following these steps.
(1) Remove rubber duct caps from all 4 bleeder
screws.
(2) Attach a clear hose to the bleeder screw at one
wheel and feed the hose into a clear jar containing
fresh brake fluid (Fig. 21).
(3) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened.
(4) Then, while the pedal is being held down, open
the bleeder screw at least 1 full turn. When the
bleeder screw opens the brake pedal will drop all the
way to the floor.
(5) Release the brake pedal only after the bleeder
screw is closed.
(6) Repeat steps 1 through 5, four or five times at
each bleeder screw. This should pass a sufficient
amount of fluid to expel all the trapped air from the
brakes hydraulic system. Be sure to monitor brake
fluid level in master cylinder fluid reservoir, to
ensure it stays at a proper level. This will ensure air
does not reenter brake hydraulic system through
master cylinder.
(7) Only after a short stroke and solid brake pedal
feel is obtained, test drive vehicle to ensure brakes
are operating correctly.
(8) Replace all 4 bleeder screw dust caps.
Fig. 19 Pressure Bleeding Adapter Mounted On
Fluid Reservoir
Fig. 20 Trapped Air in Brake Line
Fig. 21 Proper Method for Purging Air From Brake
System
300M
BRAKES
5 - 19
SERVICE PROCEDURES (Continued)
MASTER CYLINDER BLEEDING
CAUTION: When clamping the master cylinder in a
vise for bleeding, carefully tighten the vise just
enough to hold the master cylinder from moving.
Excessive pressure can damage the master cylin-
der.
(1) Clamp the master cylinder in a vise (Fig. 22).
NOTE: The master cylinder on this vehicle uses
ISO style flares and metric threads on the master
cylinder outlet ports. Special Tool Packages 8129
and 8305 have ISO style flares and metric threads
on their bleeding tubes.
(2) Position the appropriate bleeding tools from
packages, Special Tool 8129 and 8305, on the master
cylinder. Place open ends in the fluid reservoir. Then,
attach the bleeding tube fittings to the master cylin-
der outlet ports (Fig. 22).
NOTE: Make sure the open ends of the bleeding
tubes are below the surface of the brake fluid when
the reservoir is filled to the proper level.
(3) Fill reservoir with brake fluid conforming to
DOT 3 specifications such as Mopar or Equivalent.
(4) Using a wooden dowel per (Fig. 22). Depress
master cylinder pistons slowly, and then allow pis-
tons to return to released position. Repeat several
times until all air bubbles are expelled.
(5) Remove bleeding tubes from cylinder, plug out-
lets and install filler cap.
(6) Remove master cylinder from vise and install
on power brake vacuum booster.
NOTE: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der, providing that the master cylinder has been
bled and filled upon installation.
BRAKE ROTOR MACHINING
BRAKE ROTOR MACHINING
NOTE: Refacing of the rotor is not required each
time the brake pads are replaced.
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted
on-car
brake
lathe
(Fig.
23),
or
replaced.
The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle’s hub and bearing.
NOTE:
All rotors have markings for minimum
allowable thickness cast on an un-machined sur-
face of the rotor (Fig. 24) or (Fig. 25).
Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Fig. 22 Bleeding Master Cylinder
Fig. 23 Refacing Brake Rotor
5 - 20
BRAKES
300M
SERVICE PROCEDURES (Continued)
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer’s operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
SPECIFICATIONS AND LIMITS
When refacing a rotor, the required 0.08 mm (0.003
inch) TIR (Total Indicator Reading) and 0.013 mm
(0.0005 inch) thickness variation limits MUST BE
MAINTAINED. Extreme care in the operation of
rotor turning equipment is required.
CHASSIS BRAKE TUBE REPAIR
All available brake systems on this vehicle use ISO
STYLE TUBING FLARES (Fig. 26) at all chassis
brake tube to component locations, Only the con-
nection between the rear proportioning valve
and flex hose uses a double inverted flare.
Fig. 25 Rear Rotor Thickness Markings
BRAKE ROTOR REFINISHING LIMITS
Braking Rotor
Rotor Thickness
Minimum
Rotor
Thickness
Rotor
Thickness
Variation
Rotor Run
Out*
Rotor Micro
Finish
Front Rotor
25.87–26.13 mm
1.019 -1.029 in.
24.4 mm
.960 in.
.013 mm
.0005 in.
.08 mm
.003 in.
15-80 RMS
Rear Rotor
11.63–12.13 mm
.458 -.478 in.
10.4 mm
.409 in.
.013 mm
.0005 in.
.08 mm
.003 in.
15-80 RMS
* TIR Total Indicator Reading (Measured On Vehicle)
Fig. 24 Front Rotor Thickness Markings
Fig. 26 I.S.O. Style Tubing Flare And Fitting
Connection
300M
BRAKES
5 - 21
SERVICE PROCEDURES (Continued)
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