Dodge Dakota (R1). Manual — part 235
(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. 22) and hold the end under the
adapter. With a scew driver pry up on the spring
(Fig. 23) to seat the spring into the other caliper
hole.
NOTE: Verify the spring is seated properly into the
caliper holes.
(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. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
(7) Install wheel and tire assemblies. (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(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.
Fig. 21 Polishing Piston Bore
1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE
Fig. 22 Caliper
1 - CALIPER
2 - ADAPTER
3 - CALIPER SPRING
Fig. 23 Seat Caliper Spring
1 - SCREWDRIVER
2 - ADAPTER
3 - CALIPER
4 - ADAPTER
5 - CALIPER SPRING
5 - 16
BRAKES - BASE
AN
DISC BRAKE CALIPERS (Continued)
DRUM
DESCRIPTION
Drum brakes on all models are dual shoe, internal
expanding units with an automatic self adjusting
mechanism (Fig. 24). Nine inch and eleven inch
brakes are used.
OPERATION
When the brake pedal is depressed hydraulic pres-
sure pushes the rear wheel cylinder pistons outward.
The wheel cylinder push rods then push the brake
shoes outward against the brake drum. When the
brake pedal is released return springs attached to
the brake shoes pull the shoes back to there original
position.
DIAGNOSIS AND TESTING - BRAKE DRUM
The maximum allowable diameter of the drum
braking surface is indicated on the drum outer edge.
Generally, a drum can be machined to a maximum of
1.52 mm (0.060 in.) oversize. Always replace the
drum if machining would cause drum diameter to
exceed the size limit indicated on the drum.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rate gauge. The most accurate method of measure-
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial indi-
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in.). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Machine the drum
if runout or variation exceed these values. Replace
the drum if machining causes the drum to exceed the
maximum allowable diameter.
STANDARD PROCEDURES - BRAKE DRUM
MACHINING
The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim-
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
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.
Fig. 24 Brake Assembly
1 - SUPPORT PLATE
2 - RETURN SPRING
3 - ANCHOR PLATE
4 - RETURN SPRING
5 - CABLE GUIDE
6 - PARKING BRAKE LEVER
7 - ADJUSTER CABLE AND SPRING
8 - SHOE RETAINER, SPRING AND PIN
9 - SECONDARY SHOE AND LINING
10 - LEVER SPRING
11 - ADJUSTER LEVER
12 - ADJUSTER SCREW ASSEMBLY
13 - SHOE SPRING
14 - PRIMARY SHOE AND LINING
15 - PARKING BRAKE STRUT AND SPRING
AN
BRAKES - BASE
5 - 17
(5) Vacuum brake components to remove brake lin-
ing dust.
(6) Remove shoe return springs with brake spring
plier tool (Fig. 25).
(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. 26).
(14) Remove secondary brake shoe from support
plate.
(15) Remove strut and spring (Fig. 26).
(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.
CLEANING
Clean the individual brake components, including
the support plate and wheel cylinder exterior, with a
water dampened cloth or with brake cleaner. Do not
use any other cleaning agents. Remove light rust and
scale from the brake shoe contact pads on the sup-
port plate with fine sandpaper.
INSPECTION
As a general rule, riveted brake shoes should be
replaced when worn to within 0.78 mm (1/32 in.) of
the rivet heads. Bonded lining should be replaced
when worn to a thickness of 1.6 mm (1/16 in.).
Examine the lining contact pattern to determine if
the shoes are bent or the drum is tapered. The lining
should exhibit contact across its entire width. Shoes
exhibiting contact only on one side should be
replaced and the drum checked for runout or taper.
Inspect the adjuster screw assembly. Replace the
assembly if the star wheel or threads are damaged,
or the components are severely rusted or corroded.
Discard the brake springs and retainer components
if worn, distorted or collapsed. Also replace the
springs if a brake drag condition had occurred. Over-
heating will distort and weaken the springs.
Inspect the brake shoe contact pads on the support
plate, replace the support plate if any of the pads are
Fig. 25 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. 26 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
5 - 18
BRAKES - BASE
AN
DRUM (Continued)
worn or rusted through. Also replace the plate if it is
bent or distorted (Fig. 27).
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. 28).
(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.
29). 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.
30).
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.
(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.
Fig. 29 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. 27 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
Fig. 28 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
AN
BRAKES - BASE
5 - 19
DRUM (Continued)
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