Dodge Durango (DN). Manual — part 238

Installer—C-4310

Installer—D-130

Installer—D-129

Installer—6448

Installer—C-3095

Trac-lok Tools—8140

Trac-lok Tools—6960

Trac-lok Tools—C-4487

Trac-lok Tools—8139

Pinion Gauge Block—8540

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8 1/4 AND 9 1/4 AXLE

DN

SPECIAL TOOLS (Continued)

Pinion Gauge Block—8542

Arbor Discs—8541

Pinion Gauge Set

DN

8 1/4 AND 9 1/4 AXLE

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SPECIAL TOOLS (Continued)

BRAKES

TABLE OF CONTENTS

page

page

BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
REAR WHEEL ANTILOCK BRAKES . . . . . . . . . . . . 32

FOUR WHEEL ANTILOCK BRAKES. . . . . . . . . . . . 40

BASE BRAKE SYSTEM

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 3
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4
DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . . 5

DIAGNOSIS AND TESTING

BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 5
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 8
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 8
MASTER CYLINDER/POWER BOOSTER . . . . . . . . 8
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 9
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 10
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 10

SERVICE PROCEDURES

BRAKE FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . 11
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . 11
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 12
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 12
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . . 12

REMOVAL AND INSTALLATION

BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13

BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 14
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 15
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 15
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 16
DISC BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . . 17
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
REAR BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . 19
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 21
FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . . 21
REAR PARK BRAKE CABLES . . . . . . . . . . . . . . . 22
PARK BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . 23

DISASSEMBLY AND ASSEMBLY

MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 23
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 24
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 27

CLEANING AND INSPECTION

REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 27
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28

ADJUSTMENTS

REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 28
PARK BRAKE CABLE TENSIONER . . . . . . . . . . . 30

SPECIFICATIONS

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 31

SPECIAL TOOLS

BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DN

BRAKES

5 - 1

DESCRIPTION AND OPERATION

BRAKE SYSTEM

DESCRIPTION

This vehicle is equipped with front disc brakes and

rear drum brakes. The front disc brakes consist of
single piston calipers and ventilated rotors. The rear
brakes are dual brake shoe, internal expanding units
with cast brake drums. The parking brake mecha-
nism is cable operated and connected to the rear
brake secondary shoes. Power brake assist is stan-
dard equipment. A vacuum operated power brake
booster is used for all applications.

Two antilock brake systems are used on this vehi-

cle. A rear wheel antilock (RWAL) brake system is
standard. An all-wheel antilock brake system (ABS)
is available as an option.

SERVICE WARNINGS & CAUTIONS

DESCRIPTION

WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET LININGS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.

CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only

cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.

CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.

CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.

BRAKE PEDAL

DESCRIPTION

A suspended-type brake pedal is used. The pedal is

attached to the pedal support bracket with a pivot
pin and bushings. The booster push rod is attached
to the pedal with a clip. The pedal, bushings, pivot
pin and support bracket are all serviceable compo-
nents.

OPERATION

The brake pedal is attached to the booster push

rod. When the pedal is depressed, the primary
booster push rod is depressed which move the booster
secondary rod. The booster secondary rod depress the
master cylinder piston.

STOP LAMP SWITCH

DESCRIPTION

The plunger type stop lamp switch is mounted on a

bracket attached to the brake pedal support.

CAUTION: The switch can only be adjusted during
initial installation. If the switch is not adjusted prop-
erly a new switch must be installed.

OPERATION

The brake lamp switch is used to for the brake

lamp, speed control and brake sensor circuits. The
brake lamp circuit is open until the plunger is

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BRAKES

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