Dodge Sprinter. Manual — part 21
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - ISO 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.
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. 2). 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. 2).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
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.
BRAKE PADS / SHOES
REMOVAL
REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 4).
Fig. 2 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 3 Inverted Flare Tools
5 - 8
BRAKES - BASE
VA
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide bolt (Fig. 4).
(6) Remove the brake caliper (Fig. 4).
(7) Remove the brake pads (Fig. 4).
REMOVAL - FRONT (DRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 5).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide bolt (Fig. 5).
(6) Remove the brake caliper (Fig. 5).
(7) Remove the brake pads (Fig. 5).
REMOVAL - REAR (16” WHEELS) (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 6).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide pins (Fig. 6).
(6) Remove the brake caliper from the caliper
adapter (Fig. 6).
(7) Remove the retaining spring (Fig. 6).
(8) Remove the pads (Fig. 6).
Fig. 4 FRONT BRAKE PADS
1 - DISC BRAKE CALIPER
2 - GUIDE BOLT
3 - WEAR INDICATOR
4 - DISC BRAKE PADS
5 - CALIPER ADAPTER
Fig. 5 FRONT DISC BRAKE PADS WITH DUAL
REAR WHEELS
1 - DISC BRAKE CALIPER
2 - GUIDE PIN/BOLT
3 - WEAR INDICATOR
4 - BRAKE PADS
5 - BRAKE CALIPER ADAPTER
VA
BRAKES - BASE
5 - 9
REMOVAL - REAR (15” WHEELS) (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 7).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide pin (Fig. 7).
(6) Fold the top section of the brake caliper up
(Fig. 7).
(7) Remove the pads (Fig. 7).
REMOVAL - REAR (DRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 8).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide pins (Fig. 8).
(6) Remove the brake caliper from the caliper
adapter (Fig. 8).
(7) Remove the retaining spring (Fig. 8).
(8) Remove the pads (Fig. 8).
Fig. 6 REAR DISC BRAKE PADS - 16
(
WHEELS
(SRW)
1 - AXLE
2 - RETAINING SPRING
3 - OUTBOARD PADS
4 - INBOARD PAD
5 - DISC BRAKE CALIPER
6 - WEAR INDICATOR
7 - GUIDE PIN
8 - DUST CAP
Fig. 7 REAR DISC BRAKE PADS - 15” WHEELS
(SRW)
1 - CALIPER GUIDE PIN
2 - DISC BRAKE CALIPER
3 - CALIPER ADAPTER
4 - DISC BRAKE PADS
5 - RETAINING SPRING
6 - WEAR INDICATOR
5 - 10
BRAKES - BASE
VA
INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the brake pads (Fig. 4).
(2) Install the wear indicator cable and the wear
indicator (Fig. 4). Tighten to 10 N·m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to the brake caliper
adapter (Fig. 4). Tighten the guide bolt to 25 N·m
(221 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the brake pads (Fig. 5).
(2) Install the wear indicator cable and the wear
indicator (Fig. 5). Tighten to 10 N·m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to the brake caliper
adapter (Fig. 5). Tighten the guide bolt to 25 N·m
(221 in. lbs.)(M8 bolt) or Tighten the guide bolt to 30
N·m (265 in. lbs.)(M10 10.9 bolt).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - REAR (16” WHEELS) (SRW)
(1) Install the brake pads (Fig. 6).
(2) Install the wear indicator cable and the wear
indicator (Fig. 6). Tighten to 10 N·m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 6). Tighten the guide pins to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
M10 bolt.
(4) Install the retaining spring (Fig. 6).
(5) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
INSTALLATION - REAR (16” WHEELS) (SRW)
(1) Install the brake pads (Fig. 7).
(2) Install the wear indicator cable and the wear
indicator (Fig. 7). Tighten to 10 N·m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 7). Tighten the guide pin to 30 N·m
(266 in. lbs.) for M10 bolt.
(4) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the brake pads (Fig. 8).
(2) Install the wear indicator cable and the wear
indicator (Fig. 8). Tighten to 10 N·m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 8). Tighten the guide pins to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
M10 10.9 bolt.
(4) Install the retaining spring (Fig. 8).
(5) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
Fig. 8 REAR DISC BRAKE PADS WITH DUAL REAR
WHEELS
1 - WEAR INDICATOR
2 - GUIDE PIN/BOLT
3 - DISC BRAKE CALIPER
4 - RETAINING SPRING
5 - DISC BRAKE PADS
6 - CALIPER ADAPTER
VA
BRAKES - BASE
5 - 11
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