Dodge Dakota (R1). Manual — part 237
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Remove brake lines from the master cylinder
(Fig. 42).
(2) Remove mounting nuts from the master cylin-
der (Fig. 42).
(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.).
Fig. 39 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 40 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 41 Master Cylinder Bleeding–Typical
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 42 Master Cylinder
1 - MOUNTING NUT
2 - MOUNTING NUT
3 - BRAKE LINES
4 - MASTER CYLINDER
5 - 24
BRAKES - BASE
AN
MASTER CYLINDER (Continued)
(3) Install brake lines and tighten to 19 N·m (170
in. lbs.)
(4) Fill and bleed base brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal is used. The pedal is
attached to the pedal support bracket with a pivot
bolt 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.
REMOVAL
(1) Remove stop lamp switch. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING
-
EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL).
(2) Remove clip securing booster push rod to brake
pedal (Fig. 43).
(3) Remove pedal pivot pin C-clip and slide pin out
of support bracket and pedal.
(4) Remove pedal and bushings.
INSTALLATION
(1) Replace bushings if worn or damaged.
(2) Lubricate pedal bushings and pivot pin with
Mopar multi mileage grease, Lubriplate, or a silicone
grease.
(3) Install bushings in pedal and position pedal in
support.
(4) Insert pivot pin through support and pedal
bushings and install C-clip.
(5) Install booster push rod on brake pedal and
install push rod retainer clip.
(6) Install stop lamp switch. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING
-
EXTERIOR/BRAKE
LAMP SWITCH - INSTALLATION).
POWER BRAKE BOOSTER
DESCRIPTION
All models use a tandem diaphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster unit consists of a single housing
divided into two by a tandem diaphragm. The outer
edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Remove master cylinder. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/MASTER CYLINDER -
REMOVAL).
(2) Disconnect vacuum lines at booster.
(3) Remove clip securing booster push rod to brake
pedal (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/PEDAL - REMOVAL). (Fig. 44).
(4) Remove nuts from booster mounting studs (Fig.
45).
(5) Remove booster, spacer and gaskets from front
cowl panel.
Fig. 43 Brake Pedal Mounting
1 - PEDAL SUPPORT
2 - PIVOT ROD
3 - PEDAL SUPPORT
4 - BRAKE PEDAL
5 - BOOSTER ROD
6 - CLUTCH ROD
7 - CLUTCH PEDAL
8 - BRAKE PEDAL
9 - BOOSTER ROD
AN
BRAKES - BASE
5 - 25
MASTER CYLINDER (Continued)
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. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/PEDAL - INSTALLATION).
(5) Install booster check valve if removed and con-
nect vacuum hose to check valve.
(6) Install master cylinder. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/MASTER CYLINDER -
INSTALLATION).
(7) Fill and bleed brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
ROTORS
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining in a disc brake
lathe if surface scoring and wear are light.
Replace the rotor under the following conditions:
• severely scored
• tapered
• hard spots
• cracked
• below minimum thickness
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if worn below
minimum thickness, or if machining would reduce
thickness below the allowable minimum.
Rotor minimum thickness is usually specified on
the rotor hub. The specification is either stamped or
cast into the hub surface.
ROTOR RUNOUT
Check rotor lateral runout with dial indicator
C-3339 (Fig. 46). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of the
brake shoes. Position the dial indicator plunger
approximately 25.4 mm (1 in.) inward from the rotor
edge. Maximum allowable rotor runout is 0.102 mm
(0.004 in.).
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 47).
Position the micrometer approximately 25.4 mm (1
in.) from the rotor outer circumference for each mea-
surement.
Thickness should not vary by more than 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Machine
or replace the rotor if necessary.
Fig. 44 Booster Rod Clip
1 - BOOSTER ROD
2 - BRAKE PEDAL
3 - CLIP
Fig. 45 Power Brake Booster Mounting
1 - BRAKE BOOSTER
2 - SPACER
3 - FRONT COWL PANEL
4 - BRAKE PEDAL
5 - BRAKE BOOSTER ROD
5 - 26
BRAKES - BASE
AN
POWER BRAKE BOOSTER (Continued)
STANDARD PROCEDURES - DISC ROTOR
MACHINING
The disc brake rotor can be machined if scored or
worn. The lathe must machine both sides of the rotor
simultaneously with dual cutter heads. The rotor
mounting surface must be clean before placing on the
lathe. Equipment capable of machining only one side
at a time may produce a tapered rotor.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the
vehicles hub/bearing.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DISC
BRAKE
CALI-
PERS - REMOVAL).
(4) Remove retainers on wheel studs and remove
rotor.
INSTALLATION
(1) Install rotor hub and install retainers.
(2) Install brake caliper. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(3) Install wheel and tire assembly. (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(4) Remove support and lower vehicle.
(5) Depress brake pedal several time to seat brake
shoes.
WHEEL CYLINDERS
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.
DISASSEMBLY
(1) Remove push rods and boots (Fig. 48).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
CLEANING
Clean the cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air.
Do not use rags or shop towels to dry the cylinder
components. Lint from cloth material will adhere to
the cylinder bores and pistons.
Fig. 46 Checking Rotor Runout And Thickness
Variation
1 - DIAL INDICATOR
Fig. 47 Measuring Rotor Thickness
1 - MICROMETER
2 - ROTOR
AN
BRAKES - BASE
5 - 27
ROTORS (Continued)
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