Dodge Sprinter. Manual — part 20

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 worn seals, driving through deep
water puddles, or lining that has become covered
with grease and grit during repair. Contaminated lin-
ing should be replaced to avoid further brake prob-
lems.

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 pads in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors can become so scored that replacement is nec-
essary.

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.

STANDARD PROCEDURE

STANDARD PROCEDURE - MANUAL BLEEDING

Use approved brake fluid (Refer to LUBRICATION

&

MAINTENANCE/FLUID

TYPES

-

DESCRIP-

TION). 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.

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BRAKES - BASE

VA

(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 BLEED-
ING

Use approved brake fluid (Refer to LUBRICATION

&

MAINTENANCE/FLUID

TYPES

-

DESCRIP-

TION). Use fresh, clean fluid from a sealed container
at all times.

Follow the manufacturers instructions carefully

when using pressure equipment. Do not exceed the
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.

HYDRAULIC / MECHANICAL

SPECIFICATIONS

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Brake Lines

14

—

124

Master Cylinder To Brake

Booster Nut

28

—

248

Brake Caliper Adapter

Rear

M12 X 1.5 Bolt

90

66

—

Brake Caliper Adapter

Rear

M14 X 1.5 Bolt

170

125

—

Brake Caliper Adapter

Front

170

125

—

Disc Brake Rotor Locking

Bolt

Front or Rear

23

—

204

Wear Indicator To Caliper

Bolt

Front or Rear

10

—

89

Pedal Bracket to Firewall

23

—

204

Fig. 1 Bleed Hose Setup

1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID

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BRAKES - BASE

5 - 5

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Booster To Pedal Bracket

25

—

221

Brake Caliper Guide Pins

M8 Bolt

25

—

221

Brake Caliper Guide Pins

M10 Bolt

30

—

266

ALB Operating Linkage

Lever To The Rear Axle

34

25

300

Wheel Flange Ring To

Rotor

Rear

200

148

—

Wheel Flange Ring To

Rotor

Front

180

133

—

BASE BRAKE

NOTE: Do not resurface the disc brake rotors if
they are out of specifications. (Sprinter Van Rotors
must be replaced with new disc brake rotors only).

SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Front Disc Brake Caliper
Type

Dual Piston Sliding

Rear Disc Brake Caliper
Type

Single Piston Sliding

Disc Brake Caliper

Bosch

Rear Disc Brake Rotor
New
DRW

22 mm (0.866 in.)

Rear Disc Brake Rotor
Wear Limit
DRW

19 mm (0.748 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
DRW

.1 mm (0.00394 in.)

Rear Disc Brake Rotor
Max. Axial Runout
DRW

.02 mm (0.0007 in.)

Front Disc Brake Rotor
New
DRW

22 mm (0.866 in.)

Front Disc Brake Rotor
Wear Limit
DRW

19 mm (0.748 in.)

Front Disc Brake Rotor
Max. Lateral Runout
DRW

0.05 mm (0.0019 in.)

DESCRIPTION

SPECIFICATION

Front Disc Brake Rotor
Max. Axial Runout
DRW

0.02 mm (0.0007 in.)

Front Disc Brake Rotor
New
SRW

22 mm (0.866 in.)

Front Disc Brake Rotor
Wear Limit
SRW

19 mm (0.748 in.)

Front Disc Brake Rotor
Max. Lateral Runout
SRW

0.05 mm (0.0019 in.)

Front Disc Brake Rotor
Max. Axial Runout
SRW

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models 901,902

12 mm (0.47 in.)

Rear Disc Brake Rotor
Wear Limit
Models 901,902

10 mm (0.40 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
Models 901,902

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models 901,902

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models 690.611/63/64,
903

16 mm (0.629 in.)

Rear Disc Brake Rotor
Wear Limit
Models 690.611/63/64,
903

14 mm (0.55 in.)

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BRAKES - BASE

VA

DESCRIPTION

SPECIFICATION

Rear Disc Brake Rotor
Max. Lateral Runout
Models 690.611/63/64,
903

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models 690.611/63/64,
903

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

16 mm (0.629 in.)

Rear Disc Brake Rotor
Wear Limit
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

14 mm (0.55 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

0.02 mm (0.0007 in.)

Brake Booster
Type

Vacuum Diaphragm

SPECIAL TOOLS

BRAKES

SPECIAL TOOL CROSS REFERENCE CHART

MB

TOOL #

MILLER
TOOL #

DESCRIPTION

N/A

C-4007-A

GAUGE SET

N/A

9297

ADAPTERS, BRAKE
PRESSURE

000 589

18 31 00

9296

BRAKE PEDAL WINCH

GAUGE SET - C-4007-A

ADAPTERS, BRAKE PRESSURE - 9297

BRAKE PEDAL WINCH - 9296

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BRAKES - BASE

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