Dodge Durango (DN). Manual — part 242

MASTER CYLINDER

REMOVAL

(1) Remove brake lines from the master cylinder

(Fig. 17).

(2) Remove mounting nuts from the master cylin-

der (Fig. 17).

(3) Remove master cylinder.

INSTALLATION

NOTE: If master cylinder is replaced bleed cylinder
before installation.

(1) Install master cylinder on booster mounting

studs.

(2) Install mounting nuts and tighten to 18 N·m

(160 in. lbs.)

(3) Install brake lines and tighten to 19 N·m (170

in. lbs.)

(4) Fill and bleed base brake system.

POWER BRAKE BOOSTER

REMOVAL

(1) Remove master cylinder.
(2) Disconnect vacuum lines at booster.
(3) Remove clip securing booster push rod to brake

pedal (Fig. 18).

(4) Remove nuts from booster mounting studs (Fig.

19).

(5) Remove booster, spacer and gaskets from front

cowl panel.

INSTALLATION

(1) Position spacer and gaskets on booster studs.
(2) Guide booster studs into cowl panel holes and

seat booster on panel.

(3) Install and tighten booster attaching nuts to 28

N·m (250 in. lbs.).

(4) Install booster push rod on brake pedal and

install clip.

(5) Install booster check valve if removed and con-

nect vacuum hose to check valve.

(6) Install master cylinder.
(7) Fill and bleed brake system.

Fig. 17 Master Cylinder

1 – MOUNTING NUT
2 – MOUNTING NUT
3 – BRAKE LINES
4 – MASTER CYLINDER

Fig. 18 Booster Rod Clip

1 – BOOSTER ROD
2 – BRAKE PEDAL
3 – CLIP

Fig. 19 Power Brake Booster Mounting

1 – BRAKE BOOSTER
2 – SPACER
3 – FRONT COWL PANEL
4 – BRAKE PEDAL
5 – BRAKE BOOSTER ROD

DN

BRAKES

5 - 15

REMOVAL AND INSTALLATION (Continued)

DISC BRAKE CALIPER

REMOVAL

(1) Clean master cylinder reservoir and filler caps.
(2) Remove reservoir filler cap and drain approxi-

mately 1/4 of fluid from reservoir. Use clean suction
gun or similar device to drain fluid.

(3) Raise and support vehicle.
(4) Remove front wheel and tire assemblies.
(5) Bottom caliper pistons in bores with large

C-clamp. Position clamp frame on rear of caliper and
clamp screw on outboard brake shoe.

(6) Disconnect brake hose at caliper. Discard hose

fitting washers if worn, or damaged (Fig. 20).

(7) With a screw driver pry up on the caliper

spring and pull the spring out of the caliper holes.

(8) Remove caliper and brake shoes from caliper.

INSTALLATION

(1) Install brake shoes in caliper.
(2) Install caliper and shoes over rotor and into

ledges in steering knuckle. Be sure ends of brake
shoes are properly seated on slide surfaces of ledges.

(3) Install and tighten caliper slide pins to 30 N·m

(22 ft. lbs.). Start the slide pins by hand before
tightening. Do not cross thread the pins.

(4) Install caliper spring into one caliper hole and

under the adapter. Pull down on the opposite end of
the spring (Fig. 21) and hold the end under the
adapter. With a scew driver pry up on the spring
(Fig. 22) to seat the spring into the other caliper
hole.

NOTE: Verify the spring is seated properly into the
caliper holes.

Fig. 20 Caliper Brake Hose Connection

1 – CALIPER
2 – FRONT BRAKE HOSE
3 – FITTING WASHERS

Fig. 21 Caliper Spring

1 – CALIPER
2 – ADAPTER
3 – CALIPER SPRING

Fig. 22 Seat Caliper Spring

1 – SCREWDRIVER
2 – ADAPTER
3 – CALIPER
4 – ADAPTER
5 – CALIPER SPRING

5 - 16

BRAKES

DN

REMOVAL AND INSTALLATION (Continued)

(5) Install brake hose to caliper with new seal

washers and tighten fitting bolt to 24 N·m (18 ft.
lbs.).

CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.

(6) Bleed base brake system.
(7) Install wheel and tire assemblies.
(8) Remove supports and lower vehicle.
(9) Pump brake pedal to seat brake shoes.
(10) Fill brake fluid reservoir.
(11) Verify firm pedal before moving vehicle.

DISC BRAKE SHOES

REMOVAL

(1) Clean master cylinder reservoir and filler caps.
(2) Remove reservoir filler cap and drain approxi-

mately 1/4 of fluid from reservoir. Use clean suction
gun or similar device to drain fluid.

(3) Raise and support vehicle.
(4) Remove front wheel and tire assemblies.
(5) Bottom caliper pistons in bores with large

C-clamp. Position clamp frame on rear of caliper and
clamp screw on outboard brake shoe.

(6) With a screw driver pry up on the caliper

spring and pull the spring out of the caliper holes.

(7) Remove caliper slide pins.
(8) Remove caliper and brake shoes (Fig. 23).

(9) Remove outboard brake shoe (Fig. 24). Pry one

end of shoe retainer spring away from caliper. Then
tilt shoe upward and rotate it out of caliper.

(10) Remove inboard shoe by tilting shoe outward

until retainer spring is clear of caliper piston (Fig.
25).

(11) Support caliper with wire from suspension

component. Do not allow brake hose to support cali-
per weight.

INSTALLATION

(1) Clean slide surfaces of adapter ledges with a

wire brush. Then lubricate surfaces with a thin coat
of high temperature grease.

(2) Install new slide pin bushings if necessary.
(3) Install inboard shoe. Be sure retainer spring is

firmly seated in caliper piston.

(4) Insert outboard brake shoe in caliper (Fig. 26).
(5) Insure the outboard shoe retainer spring are

seated in the caliper (Fig. 27).

Fig. 23 Removing Caliper Assembly

1 – CALIPER AND BRAKE SHOES

Fig. 24 Outboard Brake Shoe

1 – SHOE SPRING
2 – OUTBOARD SHOE

Fig. 25 Inboard Brake Shoe

1 – CALIPER PISTON
2 – RETAINER SPRING
3 – INBOARD SHOE

DN

BRAKES

5 - 17

REMOVAL AND INSTALLATION (Continued)

(6) Install caliper and brake shoes over rotor and

into adapter.

(7) Install and tighten caliper slide pins to 30 N·m

(22 ft. lbs.). Start the slide pins by hand before
tightening. Do not cross thread the pins.

(8) Install caliper spring into one caliper hole and

under the adapter. Pull down on the opposite end of
the spring (Fig. 28) and hold the end under the
adapter. With a screw driver pry up on the spring
(Fig. 29) to seat the spring into the other caliper
hole.

NOTE: Verify the spring is seated properly into the
caliper holes.

(9) Install wheel and tire assembly.

Fig. 26 Installing Outboard Shoe

1 – CALIPER
2 – OUTBOARD SHOE

Fig. 27 Outboard Shoe Retainer Spring

1 – SEAT RETAINER SPRING ENDS IN CALIPER
2 – OUTBOARD SHOE

Fig. 28 Caliper Spring

1 – CALIPER
2 – ADAPTER
3 – CALIPER SPRING

Fig. 29 Seat Caliper Spring

1 – SCREWDRIVER
2 – ADAPTER
3 – CALIPER
4 – ADAPTER
5 – CALIPER SPRING

5 - 18

BRAKES

DN

REMOVAL AND INSTALLATION (Continued)