Dodge Viper SRT-10 (ZB). Manual — part 32
CAUTION: Use Bleeder Tank, Special Tool C-3496-B,
or equivalent, along with Cap, Master Cylinder
Adapter, Special Tool 6921, to pressurize the brake
system for bleeding.
Follow pressure bleeder manufacturer’s instruc-
tions, for use of pressure bleeding equipment.
When bleeding the front brakes it is necessary that
both halves of the caliper assembly be bled individu-
ally. This procedure should be followed to ensure that
the caliper assembly is adequately bled.
(1) Attach a clear hose onto bleeder screw located
on the top of the inboard half of the front caliper
assembly (Fig. 2). Put open end of clear hose into a
clear container partially filled with fresh clean brake
fluid (Fig. 2).
CAUTION:
Just
cracking
bleeder
screw
often
restricts fluid flow. This will result in a slow and
weak fluid discharge, and will NOT get all the air
out of the hydraulic system.
(2) Open bleeder screw (Fig. 2) on inboard half of
the front caliper assembly at least ONE FULL
TURN or more.
(3) Bleed 4 to 8 ounces of brake fluid through
inboard half of front caliper assembly being bled.
When an air-free flow is maintained in clear plastic
hose with no bubbles present in container, a good
and complete brake bleed is indicated.
(4) Close bleeder screw, and remove hose. Torque
inboard bleeder screw to 10 N·m (88 in. lbs.).
(5) Attach clear hose on bleeder screw located on
the top of the outboard half of front caliper assembly
being bled (Fig. 3). Put open end of hose into a clear
container partially filled with fresh clean brake fluid
(Fig. 3).
(6) Repeat steps 2 and 3 above on outboard half of
the caliper assembly. Then close the bleeder screw on
the outboard caliper.
(7)
Remove hose from bleeder screw, and torque
the bleeder screw to 10 N·m (88 in. lbs.).
Fig. 2 Bleeding Inboard Caliper Half
1 - OUTBOARD BLEEDER SCREW
2 - INBOARD BLEEDER SCREW
3 - CLEAR HOSE
4 - CLEAN BRAKE FLUID
5 - FRONT BRAKE CALIPER ASSEMBLY
Fig. 3 Bleeding Outboard Caliper Half
1 - CLEAR HOSE
2 - FRONT BRAKE CALIPER ASSEMBLY
3 - CLEAN BRAKE FLUID
4 - CLEAR HOSE
5 - 6
BRAKES - BASE
ZB
BRAKES - BASE (Continued)
(8)
Again attach clear hose to bleeder screw
located on the top of inboard half of front caliper
assembly being bled (Fig. 2). Put open end of hose
into a clear container partially filled with fresh clean
brake fluid (Fig. 2).
(9)
Again repeat steps 2 and 3 above on the
inboard half of the caliper assembly. Then close the
bleeder screw on the outboard caliper.
(10) Remove hose from bleeder screw, and torque
the bleeder screw to 10 N·m (88 in. lbs.).
MANUAL BLEEDING METHOD
NOTE: Manual bleeding of air from the hydraulic
brake system on this vehicle is not the preferred
method. Manual bleeding may not ensure all air is
adequately eliminated from the hydraulic brake
fluid.
In the event a pressure bleeder is not available the
hydraulic brake system can be manually bled. Use
the procedures and steps listed below to ensure a
good and complete bleeding of all air from the brakes
hydraulic fluid can be obtained using a manual
bleeding procedure.
NOTE: When manual bleeding, be sure to monitor
the fluid level in the master cylinder so it stays at a
proper level keeping air from re-entering the brake
system through the master cylinder.
When bleeding the front brakes it is necessary that
both halves of the caliper assembly be bled individu-
ally. This procedure should be followed to ensure that
the caliper assembly is adequately bled.
(1) Attach a clear hose onto bleeder screw located
on the top of the inboard half of the front caliper
assembly (Fig. 2). Put open end of clear hose into a
clear container partially filled with fresh clean brake
fluid (Fig. 2).
(2) Have an assistant pump the brake pedal three
or four times and hold it down before the bleeder
screw is opened.
CAUTION: “Just cracking” bleeder screw often
restricts fluid flow. This will result in a slow and
weak fluid discharge, and will NOT get all the air
out of the hydraulic system.
(3) Open bleeder screw (Fig. 2) on inboard half of
the front caliper assembly at least ONE FULL
TURN or more.
NOTE: When the bleeder screw opens, the brake
pedal should drop to the floor. Release the brake
pedal only after the bleeder screw is closed.
(4) Close the bleeder.
(5) Repeat the above steps until 4 to 8 ounces of
brake fluid is bled through inboard half of front cal-
iper assembly being bled. When an air-free flow is
maintained in clear plastic hose with no bubbles
present in container, a good and complete brake
bleed is indicated.
(6) Torque inboard bleeder screw to 10 N·m (88 in.
lbs.).
(7) Attach clear hose on bleeder screw located on
the top of the outboard half of front caliper assembly
being bled (Fig. 3). Put open end of hose into a clear
container partially filled with fresh clean brake fluid
(Fig. 3).
(8) Repeat steps 2 through 6 above on outboard
half of the caliper assembly.
(9) Again attach clear hose to bleeder screw
located on the top of inboard half of front caliper
assembly being bled (Fig. 2). Put open end of hose
into a clear container partially filled with fresh clean
brake fluid (Fig. 2).
(10) Repeat steps 2 through 6 above on the
inboard half of the caliper assembly. Then close the
bleeder screw on the outboard caliper.
(11) Remove hose from bleeder screw, and torque
the bleeder screw to 10 N·m (88 in. lbs.).
SPECIFICATIONS
BRAKE ACTUATING SYSTEM
Actuation:
Vacuum Boosted
Power Brakes
Standard
Hydraulic System
Dual Vertically Split
(Front To Rear)
Brake Pedal:
Pedal Ratio
3.48:1
Master Cylinder:
Manufacturer
Bosch
Type
Tandem Compensating
Port Design
Body Material
Anodized Aluminum
Reservoir Material
Polypropelene
Master Cylinder Bore/Stroke And Split:
Bore And Stroke
39.0 mm x 28.57 mm
(1.54 in. x 1.125 in.)
Displacement Split
Front To Rear
65 / 35
Master Cylinder Fluid Outlet Ports:
Primary Thread Size
3/8–24 UNF-2B
ZB
BRAKES - BASE
5 - 7
BRAKES - BASE (Continued)
Actuation:
Secondary Thread
Size
7/16–24 UNS-28
Outlet Fitting Type
45° Double Wall Inverted
Flare
Power Brake Booster:
Manufacturer/Type
Bosch/Vacuum Assist
Mounting Studs
3/8-16 UNRC-2A
Type
205 mm Tandem
Boost At 20 inches Of
Manifold Vacuum
4690 All
BRAKE FASTENER TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Adjustable Pedals Mounting
Nuts
28
21
250
Adjustable Pedals - Accel-
erator Mounting Nuts
12
—
105
Brake Hose (To Caliper)
Banjo Bolt
31
23
—
Brake Tube Nuts
17
12
145
Caliper Bleeder Screw
10
—
88
Caliper (Hydraulic) Mount-
ing Bolts
115
85
—
Master Cylinder Mounting
Nuts
28
21
250
Parking Brake Cable Rout-
ing Clamp Bolts
10
—
90
Parking Brake Caliper
Mounting Bolt - Upper
(Inner Hex Head)
32
24
—
Parking Brake Caliper
Mounting Bolt - Lower
52
38
—
Parking Brake Lever Mount-
ing Nut/Bolt
25
19
225
Power Brake Booster
Mounting Nuts
28
21
250
Wheel Mounting (Lug) Nuts
122
90
—
SPECIAL TOOLS
BASE BRAKE SYSTEM
Retractor, Brake Piston 6366
Remover, Bearing Cup 6454
Cap, Master Cylinder Pressure Bleed 6921
Dial Indicator C-3339A
5 - 8
BRAKES - BASE
ZB
BRAKES - BASE (Continued)
ADJUSTABLE PEDALS
SWITCH
DESCRIPTION
The adjustable pedals switch is mounted on the
lower steering column cover/knee blocker (Fig. 4).
The adjustable pedals switch adjusts the adjustable
pedals fore-and-aft. The pedals move in the direction
the switch is actuated.
REMOVAL
(1) Disconnect battery negative (-) cable from bat-
tery and isolate.
(2) Remove fasteners securing lower steering col-
umn cover/knee blocker to instrument panel (Fig. 4).
(3) Disconnect switch wiring connector (Fig. 4),
then
remove
lower
steering
column
cover/knee
blocker with adjustable pedal switch from vehicle.
(4) Remove fasteners securing switch to lower
steering column cover/knee blocker. Remove switch.
INSTALLATION
(1) Place switch in lower steering column cover/
knee blocker and install fasteners.
(2) Place lower steering column cover/knee blocker
below steering column and connect switch wiring
connector (Fig. 4).
(3) Install
lower
steering
column
cover/knee
blocker on instrument panel (Fig. 4). Install fasten-
ers.
(4) Connect battery negative (-) cable to battery.
(5) Check operation of adjustable pedals.
BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the left
side of the brake fluid reservoir on the master cylin-
der. It is clipped into the reservoir. It can be removed
from the reservoir and replaced if necessary.
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder reservoir has
dropped below an acceptable level.
As the fluid drops below the designed level, the
fluid level switch closes and grounds the red BRAKE
warning indicator circuit. This turns on the red
BRAKE warning indicator. At this time, the master
cylinder brake fluid reservoir must be checked and
filled to the FULL mark with brake fluid. Check the
entire brake hydraulic system for evidence of a leak.
CAUTION: An abnormal loss of brake fluid in the
master cylinder fluid reservoir could be caused by a
leak in the hydraulic system. The entire brake
hydraulic system should be checked for evidence
of a leak.
REMOVAL
NOTE: Before proceeding, review all Warnings and
Cautions. (Refer to 5 - BRAKES - WARNING)
(1) Remove vehicle wiring harness connector from
brake fluid level switch located in master cylinder
brake fluid reservoir (Fig. 5).
(2) Push together retaining tabs on opposite end of
switch (right side of reservoir), holding it in place in
brake fluid reservoir.
(3) Pull brake fluid level switch out of left side of
reservoir.
Fig. 4 Adjustable Pedals Switch
1 - REAR VIEW OF SWITCH
2 - LOWER STEERING COLUMN COVER
3 - WIRING CONNECTOR
4 - ADJUSTABLE PEDALS SWITCH
ZB
BRAKES - BASE
5 - 9
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