Dodge Durango (DN). Manual — part 243

(10) Remove support and lower vehicle.
(11) Pump brake pedal to seat brake shoes.
(12) Fill brake fluid reservoir.
(13) Verify a firm brake pedal before moving vehi-

cle.

DISC BRAKE ROTOR

REMOVAL

(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper.
(4) Remove retainers on wheel studs and remove

rotor.

INSTALLATION

(1) Install rotor hub and install retainers.
(2) Install brake caliper.
(3) Install wheel and tire assembly.
(4) Remove support and lower vehicle.
(5) Depress brake pedal several time to seat brake

shoes.

REAR BRAKE SHOES

REMOVAL

(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove clip nuts securing brake drum to wheel

studs.

(4) Remove drum. If drum is difficult to remove,

remove rear plug from access hole in support plate.
Back-off self adjusting by inserting a thin screw-
driver into access hole and push lever away from
adjuster screw star wheel. Then insert an adjuster
tool into brake adjusting hole rotate adjuster star
wheel to retract brake shoes.

(5) Vacuum brake components to remove brake lin-

ing dust.

(6) Remove shoe return springs with brake spring

plier tool (Fig. 30).

(7) Remove adjuster cable. Slide cable eye off

anchor pin. Then unhook and remove cable from
adjuster lever.

(8) Remove cable guide from secondary shoe and

anchor plate from anchor pin.

(9) Remove adjuster lever. Disengage lever from

spring by sliding lever forward to clear pivot and
work lever out from under spring.

(10) Remove adjuster lever spring from pivot.
(11) Disengage and remove shoe spring from brake

shoes.

(12) Disengage and remove adjuster screw assem-

bly from brake shoes.

(13) Remove brake shoe retainers, springs (Fig.

31).

Fig. 30 Shoe Return Springs

1 – SHOE RETURN SPRING
2 – SPECIAL TOOL (REMOVING AND INSTALLING)
3 – SHOE RETURN SPRING
4 – ADJUSTER CABLE
5 – LEVER SPRING
6 – ADJUSTER LEVER
7 – SHOE TO SHOE SPRING
8 – ANTI-RATTLE SPRING

Fig. 31 Shoe Retainers, Springs and Pins

1 – STRUT AND SPRING
2 – SPRING
3 – PIN
4 – RETAINER
5 – PRIMARY SHOE AND LINING
6 – TOOL C-4070
7 – SECONDARY SHOE AND LINING

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BRAKES

5 - 19

REMOVAL AND INSTALLATION (Continued)

(14) Remove secondary brake shoe from support

plate.

(15) Remove strut and spring (Fig. 31).
(16) Remove parking brake lever retaining clip

from the secondary shoe and remove the lever.

(17) Remove primary shoe from support plate.
(18) Disengage parking brake lever from parking

brake cable.

INSTALLATION

(1) Clean and inspect individual brake compo-

nents, refer to Cleaning and Inspection Section.

(2) Lubricate anchor pin and brake shoe contact

pads on support plate with high temperature grease
or Lubriplate (Fig. 32).

(3) Lubricate adjuster screw socket, nut, button

and screw thread surfaces with grease or Lubriplate.

(4) Install the parking brake cable to the parking

brake lever.

(5) Install parking brake lever to the secondary

shoe and install retaining clip.

(6) Install primary shoe on support plate. Secure

shoe with new spring retainers and pin.

(7) Install spring on parking brake strut and

engage strut in primary.

(8) Install secondary shoe on support plate (Fig.

33). Insert strut in shoe and guide shoe onto anchor
pin. Temporarily secure shoe with retaining pin.

(9) Install anchor plate and adjuster cable eyelet

on support plate anchor pin.

(10) Install cable guide in secondary shoe and posi-

tion cable in guide.

(11) Assemble

adjuster

screw

(Fig.

34).

Then

install and adjuster screw between the brake shoes.

CAUTION: Be sure the adjuster screws are installed
on the correct brake unit. The adjuster screws are
marked L (left) and R (right) for identification.

(12) Install adjuster lever and spring and connect

adjuster cable to lever.

(13) Install secondary shoe retainers and spring.

Fig. 32 Shoe Contact Surfaces

1 – ANCHOR PIN
2 – SUPPORT PLATE
3 – SHOE CONTACT SURFACES

Fig. 33 Brake Shoe Installation

1 – SHOE RETURN SPRING
2 – ANCHOR PLATE
3 – ADJUSTER CABLE
4 – SHOE RETAINING PIN
5 – SECONDARY SHOE AND LINING
6 – PRIMARY SHOE AND LINING
7 – STRUT AND SPRING

Fig. 34 Adjuster Screw

1 – WASHER
2 – SOCKET
3 – STAMPED LETTER

L-LEFT BRAKE
R-RIGHT BRAKE

4 – SCREW THREADS
5 – NUT
6 – BUTTON

5 - 20

BRAKES

DN

REMOVAL AND INSTALLATION (Continued)

(14) Install shoe spring. Connect spring to second-

ary shoe first. Then to primary shoe.

(15) Verify adjuster operation. Pull adjuster cable

upward, cable should lift lever and rotate star wheel. Be
sure adjuster lever properly engages star wheel teeth.

(16) Adjust brake shoes to drum with brake gauge.
(17) Install wheel and tire assembly.

WHEEL CYLINDER

REMOVAL

(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Disconnect wheel cylinder brake line.
(4) Remove brake shoe return springs and move

shoes out of engagement with cylinder push rods.

(5) Remove cylinder attaching bolts and remove

cylinder from support plate.

INSTALLATION

(1) Apply bead of silicone sealer around cylinder

mounting surface of support plate.

(2) Install cylinder mounting bolts and tighten to

20 N·m (15 ft. lbs.).

(3) Connect brake line to cylinder.
(4) Install brake shoe return spring.
(5) Install brake drum.
(6) Install wheel and tire assembly.
(7) Bleed base brake system.

BRAKE SUPPORT PLATE

REMOVAL

(1) Remove wheel and tire assembly and brake

drum.

(2) Remove brake shoe assembly.
(3) Remove parking brake cable from parking

brake lever.

(4) Compress parking brake cable retainer tabs.

Then push retainer and cable through and out of
support plate.

(5) Disconnect brake line at wheel cylinder.
(6) Remove wheel cylinder from support plate.
(7) Remove axle shaft, refer to Group 3 for proce-

dures.

(8) Remove bolts attaching support plate to axle

and remove support plate.

INSTALLATION

(1) Apply bead of silicone sealer around axle

mounting surface of support plate.

(2) Install support plate on axle flange. Tighten

attaching bolts to 115 N·m (85 ft. lbs.).

(3) Apply bead of silicone sealer around wheel cyl-

inder mounting surface and install wheel cylinder.

(4) Install brake line in wheel cylinder.

(5) Install parking brake cable in support plate.
(6) Install axle shaft, refer to Group 3 for proce-

dure.

(7) Connect parking brake cable to lever on sec-

ondary shoe and install brake shoes on support plate.

(8) Adjust brake shoes to drum with brake gauge.
(9) Install brake drum and wheel and tire assem-

bly.

(10) Bleed brake system.

FRONT PARK BRAKE CABLE

REMOVAL

(1) Raise and support the vehicle.
(2) Loosen the cable adjuster nut (Fig. 35).
(3) Pull cable through the body mount.
(4) Remove support and lower vehicle.
(5) Remove left kick panel.
(6) Fold left front edge of floor covering rearward

and remove cable grommet from floor pan.

(7) Engage parking brake pedal and remove cable

from park brake pedal assembly.

(8) Pull the cable through the floor pan.
(9) Remove cable from vehicle.

INSTALLATION

(1) Insert front cable through floor pan and install

grommet.

(2) Insert cable retainer into hole at bottom of

pedal assembly bracket and connect cable end.

(3) Install kick panel.
(4) Raise and support vehicle.
(5) Insert the cable through the body mount.

Fig. 35 Cable Tensioner

1 – RIGHT REAR CABLE
2 – LEFT REAR CABLE
3 – ADJUSTMENT NUT
4 – TENSIONER
5 – FRONT CABLE
6 – BODY MOUNT

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BRAKES

5 - 21

REMOVAL AND INSTALLATION (Continued)

(6) Connect the cable to the tensioner.
(7) Perform parking brake adjustment procedure.
(8) Remove support and lower vehicle.

REAR PARK BRAKE CABLES

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the rear wheel and tire assemblies.
(3) Loosen tensioner adjuster nut.
(4) Remove the right cable from the tensioner and

pull the cable housing through the left cable connec-
tor (Fig. 36).

(5) Remove the left cable connector.
(6) Pull both cables through the cable bracket.
(7) Remove the right cable mounting retainers

from the stabilzer bar retainers (Fig. 37) and remove
the cable from the differential housing (Fig. 38).

(8) Remove the brake drums.
(9) Disconnect each cable from park brake lever.
(10) Compress tabs on each cable housing retainer

at the brake support plate.

(11) Remove the cables from the brake support

plates.

INSTALLATION

(1) Push each cable housing through the brake

support plate hole until cable housing retainer tabs
lock into place.

NOTE: Pull on the cable housing to ensure it is
lock into place.

(2) Pull back on the end of the cable. Then push

the cable in to engage the cable in the park brake
lever.

NOTE: Pull on the cable end to ensure it is
attached it the park brake lever.

(3) Install the brake drums.
(4) Install right cable mounting retainers.
(5) Push the cables housing through the cable

bracket

(6) Install the left cable onto the cable connector.
(7) Push the right cable housing through the left

cable connector and connect the cable to the ten-
sioner.

(8) Install the wheel and tire assemblies.

Fig. 36 Cable Connectors

1 – CABLE BRACKET
2 – RIGHT CABLE
3 – LEFT CABLE
4 – TENSIONER CONNECTOR

Fig. 37 Stabilzer Bar Retainer

1 – RIGHT CABLE
2 – STABILIZER BAR RETAINER

Fig. 38 Cable Retainers

1 – CABLE RETAINER
2 – RIGHT CABLE
3 – DIFFERENTIAL HOUSING

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BRAKES

DN

REMOVAL AND INSTALLATION (Continued)