Chrysler New Yorker. Manual — part 22
Fig. 1 Brake Tube Nut Thread Sizes And Tube Routing
5 - 2
BRAKES
300M
GENERAL INFORMATION (Continued)
BASE BRAKE SYSTEM
INDEX
page
page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES . . . . . . . . . . . . . . 5
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 5
MASTER CYLINDER RESERVOIR FLUID LEVEL
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROPORTIONING VALVES . . . . . . . . . . . . . . . . . 5
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . 5
REAR WHEEL HUB AND BEARING . . . . . . . . . . . 8
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 7
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 8
VACUUM BOOSTER . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 17
BRAKE ROTOR THICKNESS AND RUNOUT . . . 14
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE . . . . 8
BRAKE SYSTEM DIAGNOSIS CHARTS . . . . . . . 10
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 16
REAR WHEEL HUB AND BEARING . . . . . . . . . . 18
RED BRAKE WARNING LAMP TEST . . . . . . . . . 18
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . 18
BRAKE ROTOR MACHINING . . . . . . . . . . . . . . . 20
CHASSIS BRAKE TUBE REPAIR . . . . . . . . . . . . 21
MASTER CYLINDER BLEEDING . . . . . . . . . . . . 20
MASTER CYLINDER FLUID LEVEL . . . . . . . . . . 18
REMOVAL AND INSTALLATION
CHASSIS BRAKE TUBES AND HOSES . . . . . . . 33
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 23
FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . 25
JUNCTION BLOCK (NON-ABS) . . . . . . . . . . . . . 34
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 31
PARK BRAKE INTERMEDIATE CABLE . . . . . . . . 37
PARK BRAKE LEVER (PEDAL) AND FRONT
CABLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 35
PARK BRAKE REAR CABLES . . . . . . . . . . . . . . 38
PARK BRAKE SHOES WITH REAR DISC
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PARK BRAKE TENSIONER . . . . . . . . . . . . . . . . 39
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 34
REAR DISC BRAKE CALIPER . . . . . . . . . . . . . . 26
REAR DISC BRAKE SHOES . . . . . . . . . . . . . . . . 28
REAR WHEEL HUB AND BEARING . . . . . . . . . . 30
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 40
VACUUM BOOSTER . . . . . . . . . . . . . . . . . . . . . 32
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID RESERVOIR . . . . . . . . . . . . . . . . 40
FRONT AND REAR DISC BRAKE CALIPER . . . . 41
CLEANING AND INSPECTION
CHASSIS TUBES AND HOSES . . . . . . . . . . . . . . 46
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . 45
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 46
ADJUSTMENTS
PARK BRAKE CABLE TENSIONER . . . . . . . . . . 47
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS
BRAKE ACTUATION SYSTEM . . . . . . . . . . . . . . 48
BRAKE FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 48
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIAL TOOLS
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 49
DESCRIPTION AND OPERATION
FRONT DISC BRAKES
The front disc brake assembly used on this vehicle
consists of the following components.
• Disc brake caliper
• Shoes and linings
• Rotor
• hub and bearing
Disc Brake Caliper. The floating double pin sin-
gle piston Kelsey-Hayes Family Calipers (Fig. 1) used
on this vehicle are mounted directly to the steering
knuckles and use no adapter. The caliper is mounted
to the steering knuckle using bushings, sleeves and 2
through bolts which thread directly into the steering
knuckle (Fig. 2).
The floating double pin single piston calipers, (Fig.
1) used on this vehicle are mounted directly to the
steering knuckles and use no adapter. The caliper is
mounted to the steering knuckle using bushings,
sleeves and 2 through bolts which thread directly
into the steering knuckle (Fig. 2).
Two machined abutments on the steering knuckle
(Fig. 2) position and align the caliper fore and aft.
The guide pin bolts, sleeves, and bushings control the
side-to-side movement of the caliper.
The disc brake calipers have anti-rattle clips
attached to the inner and outer brake shoe and lin-
ing assemblies (Fig. 1). The brake caliper also has
brake shoe retractor clips to help pull the front disc
brake shoes away from the rotor (Fig. 1).
300M
BRAKES
5 - 3
WARNING:
THE PISTONS THAT ARE USED IN THE
FRONT AND REAR DISC BRAKE CALIPER ASSEM-
BLIES ARE UNIQUE TO THE CALIPER THEY ARE
USED IN. THE DIMENSIONS OF THESE PISTONS
ARE DIFFERENT, DO NOT INTERCHANGE THE
CALIPER PISTONS. IMPROPER USE COULD CAUSE
A COMPLETE FAILURE OF THE BRAKE SYSTEM.
The caliper is a one piece casting with the inboard
side containing a single piston cylinder bore. The
front disc brake caliper phenolic piston is 60 mm
(2.36 inch) in diameter.
A square cut rubber piston seal is located in a
machined groove in the cylinder bore. This provides a
hydraulic seal between the piston and the cylinder
wall (Fig. 3). The piston seal is designed to pull the
piston back into the bore of the caliper when the
brake pedal is released. This, along with the brake
shoe retractor clips, maintains the proper brake shoe
to rotor clearance.
A molded rubber dust boot is installed in a groove
in the cylinder bore and the piston, keeping contam-
ination from the cylinder wall and the piston (Fig. 3).
As brake shoe linings wear, master cylinder reser-
voir brake fluid level will go down. If brake fluid has
been added to the reservoir, reservoir overflow may
occur when the piston is pushed back into the new
lining position. Overflowing can be avoided in this
case by removing a small amount of fluid from the
master cylinder reservoir.
Brake Shoes. The brake shoe lining material used
has been specifically formulated to meet the braking
requirements of the vehicle. When brake shoes are
replaced, only brake shoes meeting the original
equipment manufacturer formulation (such as Mopar
Fig. 1 Front Disc Brake Caliper Assembly
Fig. 2 Disc Brake Caliper Mounting
Fig. 3 Piston Seal Function for Automatic
Adjustment Of Front Brakes
5 - 4
BRAKES
300M
DESCRIPTION AND OPERATION (Continued)
replacement parts) should be used. This will main-
tain the original braking performance of this vehicle.
An audible wear indicator (Fig. 1) is mounted on the
outboard pad of the front disc brake assemblies.
Upon contact with the brake rotor, this indicator
emits a sound, signaling that brake shoes may need
inspection and/or replacement.
Rotor. The purpose of the rotor is to slow down
and stop the front wheels of the vehicle. This is
accomplished by applying the brake shoes against
the braking surfaces of the rotor. The rotor is made
of iron and is vented to help cool it during brake
applications.
Hub and Bearing. The hub and bearing is used
to mount the front brake rotor and wheel. The rotor
is mounted to the front face of the hub by the wheel
mounting studs and retained by the wheel mounting
nuts. The hub/bearing is mounted to the steering
knuckle using four mounting bolts.
REAR DISC BRAKES
The rear disc brakes are similar to front disc
brakes, however, there are several distinctive fea-
tures that require different service procedures. This
single piston, floating caliper rear disc brake assem-
bly includes a hub and bearing assembly, adapter,
braking disc (rotor), caliper, shoes and linings. The
parking brake system on all vehicles equipped with
rear disc brakes, consists of a small duo-servo drum
brake mounted to the caliper adapter. The drum
brake shoes expand out against a braking surface
(hat section) on the inside area of the rotor.
This vehicle is equipped with a caliper assembly
that has a 36 mm (1.42 in.) piston and uses a 14 inch
solid non-vented rotor.
The caliper assembly on all applications float on
rubber bushings using internal metal sleeves which
are attached to the adapter using threaded guide pin
bolts.
The adapter and disc shield are mounted to the
rear suspension knuckles of vehicle. The adapter is
used to mount the brake shoes and actuating cables
for the parking brake system. The adapter also
mounts the rear caliper assembly to the vehicle. The
adapter has two machined abutments which are used
to position and align the caliper and brake shoes for
movement inboard and outboard (Fig. 4).
PARKING BRAKE
The
parking
brake
mechanism
on
vehicles
equipped with rear disc brakes, consists of a small
duo-servo brake which is mounted to the disc brake
caliper adapter. The hat (center) section (Fig. 5) of
the rear rotor serves as the braking surface (drum)
for the parking brakes.
The parking brake shoes are mechanically oper-
ated by an internal lever connected to a flexible steel
cable. The wheel brake (rear) cables are joined at an
equalizer which is attached to the intermediate cable.
The intermediate cable is attached to the front cable
leading to the foot lever.
PROPORTIONING VALVES
ANTILOCK AND NON-ANTILOCK BRAKES
Two in line proportioning valves (Fig. 6) are used
on both the Teves Mark 20 Antilock Brake System
and on all Non-Antilock Brake applications. One
valve is used for each rear brake hydraulic circuit.
On light pedal applications equal brake pressure
will be transmitted to the front and rear brakes. On
heavier pedal applications the pressure transmitted
to the rear will be lower than the front brakes. This
will prevent premature rear wheel skid. If hydraulic
pressure is lost in one half of the diagonally split sys-
tem, the operation of the proportioning valve in the
remaining half is not effected.
The in-line proportioning valves are located in the
rear of the vehicle, at the rear brake flex hose. The
proportioning valves are not serviceable, but are a
replaceable component.
CHASSIS TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The chassis tubes are steel with a corro-
sion resistant coating applied to the external surfaces
and the flex hoses are made of reinforced rubber. The
rubber flex hoses allow for the movement of the vehi-
cles suspension.
MASTER CYLINDER
Only one master cylinder is available for all appli-
cations. A Bosch center valve master cylinder is used.
The only serviceable components on the master cyl-
inder assembly is the reservoir and sealing grom-
mets. The master cylinder itself, cannot be serviced,
and must be replaced as an assembly, if found to be
defective.
The reservoir is indexed to prevent installation in
the wrong direction. The cap diaphragm is slit to
allow atmospheric pressure to equalize on both sides
of the diaphragm.
The primary and secondary outlet tubes of the
master cylinder are connected to a junction block on
non-ABS equipped vehicles. The master cylinder pri-
mary outlet port connects to the inboard port of the
junction block, and the secondary outlet port con-
nects to the outboard port of the junction block. The
300M
BRAKES
5 - 5
DESCRIPTION AND OPERATION (Continued)
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