Dodge Durango (DN). Manual — part 244

(9) Perform park brake adjustment procedure.
(10) Remove support and lower the vehicle.

PARK BRAKE PEDAL ASSEMBLY

Removal

(1) Remove left side kick panel.
(2) Remove brake release rod from pedal assembly

(Fig. 39).

(3) Disconnect brake warning lamp switch.
(4) Remove front parking brake cable.
(5) Remove mounting nuts and mounting bolt.
(6) Slide assembly rearward off the mounting

studs (Fig. 39).

Installation

(1) Install assembly on the mounting studs.
(2) Install mounting bolt and nuts.
(3) Install front parking brake cable.
(4) Connect brake warning lamp switch.
(5) Install brake release rod to pedal assembly.
(6) Install left side kick panel.

DISASSEMBLY AND ASSEMBLY

MASTER CYLINDER RESERVOIR

REMOVAL

(1) Remove reservoir cap and empty fluid into

drain container.

(2) Clamp cylinder body in vise with brass protec-

tive jaws.

(3) Remove pins that retain reservoir to master

cylinder. Use hammer and pin punch to remove pins
(Fig. 40).

(4) Loosen reservoir from grommets with pry tool

(Fig. 41).

(5) Remove reservoir by rocking it to one side and

pulling free of grommets (Fig. 42).

(6) Remove old grommets from cylinder body (Fig.

43).

Fig. 39 Parking Brake Pedal Assembly

1 – PARKING BRAKE ASSEMBLY
2 – LEFT COWL PANEL
3 – FRONT CABLE
4 – RELEASE ROD

Fig. 40 Reservoir Retaining Pins

1 – PIN PUNCH
2 – RESERVOIR
3 – BODY
4 – ROLL PINS

Fig. 41 Loosening Reservoir

1 – PRY TOOL
2 – RESERVOIR
3 – GROMMET
4 – MASTER CYLINDER BODY

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REMOVAL AND INSTALLATION (Continued)

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 new grommets with clean brake fluid

and Install new grommets in cylinder body (Fig. 44).
Use finger pressure to install and seat grommets.

(2) Start reservoir in grommets. Then rock reser-

voir back and forth while pressing downward to seat
it in grommets.

(3) Install pins that retain reservoir to cylinder

body.

(4) Fill and bleed master cylinder on bench before

installation in vehicle.

DISC BRAKE CALIPER

DISASSEMBLY

(1) Drain old brake fluid out of caliper into drain

pan.

(2) Remove piston dust boot (Fig. 45). Use screw-

driver to push boot out of groove.

(3) Pad outboard shoe side of caliper interior with

a minimum 1 inch thickness of shop towels (Fig. 46).
Towels will prevent piston damage when piston
comes out of the caliper bore.

(4) Remove caliper piston with short bursts of com-

pressed air. Apply air pressure through fluid inlet
port of caliper (Fig. 46).

Fig. 42 Reservoir Removal

1 – RESERVOIR
2 – GROMMETS

Fig. 43 Grommet Removal

1 – MASTER CYLINDER BODY
2 – GROMMETS

Fig. 44 Grommet Installation

1 – WORK NEW GROMMETS INTO PLACE USING FINGER

PRESSURE ONLY

Fig. 45 Piston Dust Boot

1 – PISTON BOOT DUST

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DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.

(5) Remove caliper piston seal with wood pencil or

plastic tool (Fig. 47). Do not use metal tools as they
will scratch piston bore.

(6) Remove caliper slide pin bushings and boots.
(7) Remove caliper bleed screw and cap.

ASSEMBLY

(1) Lubricate slide pin boots and bushings with

GE, or Dow silicone grease. Then install the boots
and bushings in caliper.

(2) Coat caliper piston bore, piston and new piston

seal with clean brake fluid.

(3) Install new piston seal in caliper bore. Press

seal into groove with finger (Fig. 48). Lubricate seal
and caliper bore with additional, fresh brake fluid
after seal installation.

(4) Apply light coat of GE 661, Dow 111 or similar

silicone grease to edge and groove of piston and dust
seal. Grease acts as corrosion protection for these
areas.

Fig. 46 Caliper Piston

1 – AIR GUN NOZZLE
2 – FLUID INLET PORT
3 – CALIPER PISTON
4 – PADDING MATERIAL (TO PROTECT PISTON)

Fig. 47 Caliper Piston Seal

1 – PISTON SEAL
2 – WOOD PENCIL

Fig. 48 Caliper Piston Seal

1 – CALIPER PISTON SEAL

(PRESS SEAL INTO PLACE WITH FINGER)

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DISASSEMBLY AND ASSEMBLY (Continued)

(5) Slide new seal boot over piston until boot lip

seats in piston groove (Fig. 49).

(6) Push retainer part of boot forward until folds

in boot snap into place (Fig. 50).

(7) Start caliper piston in bore with a twisting

motion. When piston is started in seal, push piston
only part way into bore (Fig. 51). Maintain uniform
pressure on piston to avoid cocking it in bore.

(8) Press caliper piston to bottom of bore.
(9) Seat piston dust boot with Installer 8248 and

Handle C-4171 (Fig. 52).

Fig. 49 Sliding Boot Onto Piston

1 – CALIPER PISTON
2 – SLIDE DUST BOOT DOWNWARD OVER PISTON

Fig. 50 Snapping Boot Folds Into Place

1 – FOLD DUST BOOT UPWARD UNTIL IT “SNAPS” INTO PLACE
2 – CALIPER PISTON

Fig. 51 Installing Caliper Piston And Boot

1 – DUST BOOT
2 – CALIPER PISTON

Fig. 52 Seating Piston Dust Boot

1 – SEAL INSTALLER
2 – DUST BOOT

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DISASSEMBLY AND ASSEMBLY (Continued)