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BRAKES

TABLE OF CONTENTS
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BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . 65
BASE BRAKE SYSTEM
TABLE OF CONTENTS
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DESCRIPTION AND OPERATION
BASE BRAKE SYSTEM OPERATION. . . . . . . . . . . 2
BASE BRAKE SYSTEM COMPONENTS. . . . . . . . . 2
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM DIAGNOSIS CHARTS . . . . 9
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 11
DRUM BRAKE AUTOMATIC ADJUSTER. . . . . . . . 12
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . 15
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 17
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING . . . . . . . . . . . . 17
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 17
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 19
BRAKE TUBE REPAIR . . . . . . . . . . . . . . . . . . . . . 19
BRAKE ROTOR MACHINING . . . . . . . . . . . . . . . . 21
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 22
PARKING BRAKE AUTOMATIC ADJUSTER
LOCK OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS . . . . . . . . 23
BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 27
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE FLUID RESERVOIR. . . . . . . . . . . . . . . . . 29
BRAKE FLUID LEVEL SWITCH . . . . . . . . . . . . . . 30
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 30
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . 32
BRAKES TUBES AND HOSES . . . . . . . . . . . . . . . 33
DISC BRAKE CALIPER (FRONT) . . . . . . . . . . . . . 33
DISC BRAKE SHOES (FRONT) . . . . . . . . . . . . . . 35
BRAKE ROTOR (FRONT). . . . . . . . . . . . . . . . . . . 37
DISC BRAKE CALIPER (REAR) . . . . . . . . . . . . . . 38
DISC BRAKE SHOES (REAR) . . . . . . . . . . . . . . . 39
BRAKE ROTOR (REAR) . . . . . . . . . . . . . . . . . . . . 41
DRUM BRAKE WHEEL CYLINDER (REAR) . . . . . 41
DRUM BRAKE SHOES (REAR) . . . . . . . . . . . . . . 43
BRAKE DRUM (REAR) . . . . . . . . . . . . . . . . . . . . . 45
DRUM BRAKE SHOE SUPPORT PLATE
(REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PARKING BRAKE LEVER. . . . . . . . . . . . . . . . . . . 48
PARKING BRAKE CABLE (REAR) . . . . . . . . . . . . 49
PARKING BRAKE SHOES (REAR DISC
BRAKE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER (FRONT AND REAR) . . . . 55
CLEANING AND INSPECTION
BRAKE TUBES AND HOSES . . . . . . . . . . . . . . . . 59
DISC BRAKES (FRONT). . . . . . . . . . . . . . . . . . . . 59
DISC BRAKES (REAR). . . . . . . . . . . . . . . . . . . . . 60
DRUM BRAKES (REAR). . . . . . . . . . . . . . . . . . . . 60
ADJUSTMENTS
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 61
DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 61
PARKING BRAKE SHOES (REAR DISC
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BRAKE ACTUATION SYSTEM . . . . . . . . . . . . . . . 63
BRAKE FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 63
SPECIAL TOOLS
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 64
PL BRAKES 5 - 1
DESCRIPTION AND OPERATION
BASE BRAKE SYSTEM OPERATION
When a vehi cl e needs to be stopped, the dri ver
appl i es the brake pedal . The brake pedal pushes the
i nput rod of the power brake booster i nto the booster.
The booster uses vacuum to ease pedal effort as force
i s transferred through the booster to the master cyl -
i nder. The booster’s output rod pushes i n the master
cyl i nder’s pri mary and secondary pi stons appl yi ng
hydraul i c pressure through the chassi s brake tubes
and proporti oni ng val ves (rear onl y) to the brakes at
each ti re and wheel assembl y.
Front di sc brakes control the braki ng of the front
wheel s; rear braki ng i s control l ed by rear drum
brakes as standard equi pment. Rear di sc brakes and
an anti l ock brake system (ABS) wi th tracti on control
are opti onal .
The hydraul i c brake system i s di agonal l y spl i t on
both the non-anti l ock and anti l ock braki ng systems.
Thi s means the l eft front and ri ght rear brakes are
on one hydraul i c ci rcui t and the ri ght front and l eft
rear are on the other.
Vehi cl es equi pped wi th the opti onal anti l ock brake
system (ABS) use a system desi gnated Mark 20e.
Thi s system shares most base brake hardware used
on vehi cl es wi thout ABS. A vehi cl e equi pped wi th
ABS, however, uses a di fferent master cyl i nder and
brake tubes. Al so i ncl uded i n the ABS system i s an
i ntegrated control uni t (I CU) and four wheel speed
sensors. These components are descri bed i n detai l i n
the ANTI LOCK BRAKE SYSTEM secti on i n thi s
group of the servi ce manual . Al l vehi cl es wi th ABS
come standard wi th four-wheel -di sc brakes and trac-
ti on control .
The parki ng brakes are hand-operated. When
appl i ed, the parki ng brake l ever pul l s on cabl es that
actuate brake shoes at each rear wheel . The parki ng
brake l ever has an automati c adjusti ng feature that
takes up any excessi ve sl ack i n the parki ng brake
cabl e system.
BASE BRAKE SYSTEM COMPONENTS
BRAKE PEDAL
A suspended-type brake pedal i s used on thi s vehi -
cl e. The pedal pi vots on a shaft mounted i n the pedal
support bracket under the i nstrument panel . The
pedal connects to the power brake booster i nput rod
and pushes i t i n when the pedal i s appl i ed.
The brake pedal and i t’s pad are servi ceabl e sepa-
ratel y.
POWER BRAKE BOOSTER
There are two di fferent power brake booster
desi gns, al though external l y they appear the same.
Al l vehi cl es use a 205 mm tandem di aphragm power
brake booster. The two boosters are i nternal l y tuned
di fferentl y dependi ng on whether the vehi cl e i s
equi pped wi th the standard front di sc/rear drum
brake combi nati on or the opti onal front di sc/rear di sc
(four-wheel di sc) brake combi nati on. I f the power
brake booster requi res repl acement, be sure i t i s
repl aced wi th the correct part.
The power brake booster can be i denti fi ed by the
tag attached to the body of the booster assembl y (Fi g.
1). Thi s tag contai ns the fol l owi ng i nformati on: The
producti on part number of the power brake booster,
the date i t was bui l t and who manufactured i t.
The power brake booster reduces the amount of
force requi red by the dri ver to obtai n the necessary
hydraul i c pressure to stop the vehi cl e.
The power brake booster i s vacuum-operated. The
vacuum i s suppl i ed from the i ntake mani fol d on the
engi ne through the power brake booster check val ve
(Fi g. 2).
As the brake pedal i s depressed, the power booster
i nput rod moves forward. Thi s opens and cl oses
val ves i n the power brake booster, al l owi ng atmo-
spheri c pressure to enter on one si de of a di aphragm.
Engi ne vacuum i s al ways present on the other si de.
Thi s di fference i n pressure forces the output rod of
the power booster out agai nst the pri mary pi ston of
the master cyl i nder. As the pi stons i n the master cyl -
i nder move forward, hydraul i c pressure i s created i n
the brake system.
Fig. 1 Master Cylinder and Power Brake Booster
1 – POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 – POWER BRAKE BOOSTER
3 – BRAKE FLUID PRESSURE SWITCH
4 – MASTER CYLINDER
5 - 2 BRAKES PL
The power brake vacuum booster assembl y mounts
on the engi ne si de of the dash panel . The booster
i nput push rod connects to the brake pedal . A vac-
uum l i ne connects the power booster to the i ntake
mani fol d. The master cyl i nder i s bol ted to the front
of the power brake booster.
MASTER CYLINDER
The base brakes on a vehi cl e not equi pped wi th
ABS use a standard compensati ng port master cyl i n-
der, whi l e vehi cl es equi pped wi th ABS use a center
val ve desi gn master cyl i nder. The i nformati on pro-
vi ded here appl i es onl y to the non-ABS master cyl i n-
der. For i nformati on on the master cyl i nder used on
vehi cl es wi th ABS, refer to the ANTI LOCK BRAKE
SYSTEM secti on i n thi s servi ce manual group.
The non-ABS master cyl i nder i s a four-outl et
desi gn wi th two screw-i n proporti oni ng val ves. One i s
attached di rectl y to the i nboard si de of the master
cyl i nder housi ng whi l e the other i s attached to the
bottom (Fi g. 3). Vehi cl es equi pped wi th rear drum
brakes use a master cyl i nder wi th a 22.23 mm (0.875
i n.) bore di ameter, whi l e vehi cl es equi pped wi th rear
di sc brakes use a 23.82 mm (0.937 i n.) bore di ameter
master cyl i nder.
The master cyl i nder body i s an anodi zed al umi num
casti ng. I t has a machi ned bore to accept the master
cyl i nder pi ston and al so has threaded ports wi th
seats for hydraul i c brake l i ne connecti ons.
The master cyl i nder’s pri mary outl et ports suppl y
hydraul i c pressure to the ri ght front and l eft rear
brakes whi l e the secondary outl et ports suppl y
hydraul i c pressure to the l eft front and ri ght rear
brakes (Fi g. 3).
BRAKE FLUID RESERVOIR
The master cyl i nder has the brake fl ui d reservoi r
mounted on top of i t whi ch gravi ty feeds brake fl ui d
to the master cyl i nder when i t i s requi red. The res-
ervoi r i s made of see-through pl asti c and i t houses
the brake fl ui d l evel swi tch.
BRAKE FLUID LEVEL SWITCH
The brake fl ui d l evel swi tch i s l ocated i n the brake
fl ui d reservoi r on the master cyl i nder (Fi g. 1). I t
senses the l evel of the brake fl ui d wi thi n the reser-
voi r and when the l evel drops bel ow an acceptabl e
l evel , the swi tch cl oses and compl etes the ground ci r-
cui t for the red BRAKE warni ng l amp. Thi s turns on
the red BRAKE warni ng l amp. For addi ti onal i nfor-
mati on, refer to RED BRAKE WARNI NG LAMP al so
i n thi s secti on.
PROPORTIONING VALVE
NOTE: Only vehicles without antilock brakes have
proportioning valves. Vehicles with antilock brakes
have electronic brake distribution that is built into
the integrated control unit.
Fig. 2 Power Brake Booster
1 – MOUNTING STUD
2 – PARTS IDENTIFICATION TAG
3 – MASTER CYLINDER MOUNTING STUDS
4 – VACUUM CHECK VALVE
Fig. 3 Non-ABS Master Cylinder
1 – RIGHT FRONT BRAKE TUBE
2 – LEFT FRONT BRAKE TUBE
3 – LEFT REAR BRAKE TUBE
4 – REAR PROPORTIONING VALVES
5 – RIGHT REAR BRAKE TUBE
PL BRAKES 5 - 3
DESCRIPTION AND OPERATION (Continued)
Proporti oni ng val ves bal ance front to rear braki ng
by control l i ng the brake fl ui d hydraul i c pressure to
the rear brakes. Under l i ght pedal appl i cati on, the
proporti oni ng val ve al l ows normal fl ui d fl ow to the
rear brakes. Under hi gher pedal effort, the val ve
reduces fl ui d pressure to the rear brakes.
The non-anti l ock master cyl i nder i s a four-outl et
desi gn wi th two screw-i n proporti oni ng val ves
attached di rectl y to the master cyl i nder housi ng (Fi g.
3). One proporti oni ng val ve control s each rear brake.
BRAKE TUBES AND HOSES
The purpose of the brake tubes and fl ex hoses i s to
transfer the pressuri zed brake fl ui d devel oped by the
master cyl i nder to the brakes at each wheel of the
vehi cl e. The fl ex hoses connect the chassi s brake
tubes, whi ch are mounted to the vehi cl e’s underbody,
to the brake at each wheel , al l owi ng for movement of
the vehi cl e’s suspensi on. The brake tubes are steel
wi th a corrosi on-resi stant nyl on coati ng appl i ed to
the external surfaces. The fl ex hoses are made of
rei nforced rubber.
DISC BRAKES (FRONT)
The front di sc brakes consi st of the fol l owi ng com-
ponents (Fi g. 4):
• Brake cal i per - si ngl e-pi ston, fl oati ng type
• Brake shoes and l i ni ngs
• Brake rotor
When the brakes are appl i ed, fl ui d pressure i s sent
to each brake cal i per. The pressure at the cal i per i s
exerted equal l y agai nst the cal i per pi ston. The pres-
sure appl i ed to the pi ston i s transmi tted di rectl y to
the i nboard brake shoe. Thi s forces the shoe l i ni ng
agai nst the i nner surface of the brake rotor. At the
same ti me, fl ui d pressure wi thi n the cal i per pi ston
bore forces the cal i per to sl i de i nward on i ts gui de
pi ns. Thi s acti on bri ngs the outboard shoe l i ni ng i nto
contact wi th the outer surface of the brake rotor.
Thi s pressure on both si des of the brake rotor causes
fri cti on, bri ngi ng the vehi cl e to a stop.
BRAKE CALIPER
The cal i per i s a one-pi ece casti ng wi th the i nboard
si de contai ni ng a si ngl e pi ston cyl i nder bore (Fi g. 5).
The front di sc brake cal i per pi ston, i s manufac-
tured from a phenol i c compound. The outsi de di ame-
ter of the cal i per pi ston i s 54 mm.
A square-cut rubber pi ston seal i s l ocated i n a
machi ned groove i n the cal i per cyl i nder bore. Thi s
provi des a hydraul i c seal between the pi ston and the
cyl i nder wal l (Fi g. 6). The pi ston seal i s desi gned to
pul l the pi ston back i nto the bore of the cal i per when
the brake pedal i s rel eased. Thi s mai ntai ns the
proper brake shoe-to-rotor cl earance.
A rubber dust boot i s i nstal l ed i n the cyl i nder bore
openi ng and i n a groove i n the pi ston (Fi g. 6). Thi s
prevents contami nati on i n the bore area.
The cal i per i s mounted to the steeri ng knuckl e
usi ng bushi ngs, sl eeves and two gui de pi n bol ts (Fi g.
5). The gui de pi n bol ts thread di rectl y i nto bosses on
the steeri ng knuckl e.
Two machi ned abutments on the steeri ng knuckl e
posi ti on the cal i per. The gui de pi n bol ts, sl eeves, and
bushi ngs control the si de-to-si de movement of the
cal i per. Al l of the front brake force generated duri ng
braki ng of the vehi cl e i s taken up di rectl y by the
steeri ng knuckl es of the vehi cl e.
BRAKE SHOES AND LININGS
There are two brake shoes mounted to each cal i per,
one i nboard and one outboard (Fi g. 5). When brake
shoes are repl aced, onl y brake shoes meeti ng the
ori gi nal equi pment manufacturer (OEM) formul ati on
(such as Mopar௡ repl acement parts) shoul d be used.
As front di sc brake shoe l i ni ngs wear, master cyl -
i nder reservoi r brake fl ui d l evel wi l l drop. Fl ui d l evel
shoul d be checked after repl aci ng shoes.
Front di sc brakes are equi pped wi th an audi bl e
wear i ndi cator on the outboard brake pad (Fi g. 5).
Thi s sensor emi ts a sound when the brake l i ni ng
may need i nspecti on or repl acement.
Fig. 4 Front Disc Brakes
1 – STEERING KNUCKLE
2 – BRAKE PADS AND LININGS
3 – BRAKE ROTOR
4 – DRIVING HUB
5 – CALIPER ASSEMBLY
5 - 4 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
BRAKE ROTOR
The brake shoe l i ni ngs contact the brake rotor.
Each front brake rotor i s vented to hel p cool i t duri ng
and after brake appl i cati ons. I t i s mounted on the
studs of the front wheel beari ng hub.
DRUM BRAKES (REAR)
Rear drum brakes are standard equi pment on thi s
vehi cl e. The rear drum brakes consi st of the major
components l i sted i n the fi gure (Fi g. 7). Other com-
ponents rel ated to the brake shoes themsel ves can be
seen i n the next fi gure (Fi g. 8).
The rear wheel drum brakes are a two-shoe, i nter-
nal -expandi ng type wi th an automati c adjuster screw
(Fi g. 8). The automati c adjuster screw i s actuated
each ti me the brakes are appl i ed. The automati c
adjuster screw i s l ocated di rectl y bel ow the rear
brake wheel cyl i nder.
Fig. 5 Front Disc Brake Caliper
1 – CALIPER GUIDE PIN BOLT
2 – SLEEVE
3 – BUSHING
4 – CALIPER
5 – PISTON SEAL
6 – PISTON
7 – DUST SEAL
8 – WEAR INDICATOR
9 – ANTI-RATTLE CLIP
10 – BRAKE SHOE
11 – BRAKE SHOE
12 – ANTI-RATTLE CLIP
13 – BUSHING
14 – SLEEVE
15 – CALIPER GUIDE PIN BOLT
16 – CAP
17 – BLEEDER SCREW
Fig. 6 Piston Seal Function
1 – PISTON
2 – CYLINDER BORE
3 – PISTON SEAL BRAKE PRESSURE OFF
4 – CALIPER HOUSING
5 – DUST BOOT
6 – PISTON SEAL BRAKE PRESSURE ON
PL BRAKES 5 - 5
DESCRIPTION AND OPERATION (Continued)
DISC BRAKES (REAR)
Rear di sc brakes are opti onal equi pment on some
model s of thi s vehi cl e (Fi g. 9). The rear di sc brakes
are si mi l ar to the front di sc brakes; however, there
are several di sti ncti ve features that requi re di fferent
servi ce procedures. The rear di sc brakes consi st of
the fol l owi ng components:
• Brake cal i per - si ngl e-pi ston, fl oati ng type
• Brake cal i per adapter
• Brake shoe and l i ni ngs
• Brake rotor - drum-i n-hat type
Al l vehi cl es equi pped wi th rear di sc brakes have a
smal l duo-servo drum brake mounted to the cal i per
adapter. Thi s i s part of the parki ng brake system.
The drum brake shoes expand out agai nst a braki ng
surface (hat secti on) on the i nsi de area of the di sc
brake rotor.
BRAKE CALIPER
Vehi cl es are equi pped wi th a cal i per assembl y that
has a 34 mm (1.43 i n.) pi ston and uses a sol i d non-
vented rotor.
The cal i per assembl y for al l appl i cati ons fl oats on
rubber bushi ngs usi ng i nternal metal sl eeves that
are attached to the adapter usi ng threaded gui de pi n
bol ts.
BRAKE CALIPER ADAPTER
The brake cal i per adapter and rotor shi el d are
mounted to the rear suspensi on knuckl es of vehi cl e.
Fig. 7 Rear Drum Brakes
1 – DUST CAP
2 – NUT
3 – DRUM
4 – HUB AND BEARING
5 – WHEEL CYLINDER
6 – SEAL
7 – SUPPORT PLATE
8 – BRAKE SHOES
9 – RETAINER CLIP
Fig. 8 Drum Brake Shoes (Left Side Shown)
1 – WHEEL CYLINDER
2 – AUTOMATIC ADJUSTER SCREW ASSEMBLY
3 – RETURN SPRING
4 – HOLD DOWN CLIP
5 – HOLD DOWN CLIP
6 – AUTOMATIC ADJUSTER LEVER AND SPRING
7 – PARK BRAKE LEVER
8 – PARK BRAKE CABLE
9 – FRONT BRAKE SHOE
10 – BRAKE SHOE TO ANCHOR SPRING
11 – BRAKE ANCHOR PLATE
12 – REAR BRAKE SHOE
Fig. 9 Rear Disc Brakes
1 – DISC BRAKE CALIPER
2 – DISC BRAKE ADAPTER
3 – GUIDE PIN BOLTS
4 – HUB AND BEARING
5 – BRAKE ROTOR
6 – RETAINER CLIP
7 – DUST CAP
8 – NUT
5 - 6 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
The adapter i s used to mount the brake cal i per to the
vehi cl e (Fi g. 9). The adapter has two machi ned abut-
ments, whi ch are used to posi ti on and al i gn the cal -
i per and brake pads for movement i nboard and
outboard. The adapter al so mounts the parki ng brake
shoes and actuati ng cabl es to the vehi cl e.
PARKING BRAKES
The parki ng brakes (Fi g. 4) consi st of the fol l owi ng
components:
• Hand-operated park brake l ever - automati c-ad-
justi ng
• Parki ng brake cabl es
• Actuati on l evers and struts
• Duo-servo parki ng brake assembl y (rear di sc
onl y)
PARKING BRAKE LEVER
Al l vehi cl es are equi pped wi th a center-mounted,
hand-operated parki ng brake l ever mounted between
the front seats (Fi g. 10). Thi s l ever i s an automati c-
adjusti ng type that conti nuousl y appl i es mi ni mal
tensi on to the parki ng brake cabl es to keep them i n
adjustment at al l ti mes. Due to thi s feature, the
parki ng brake cabl e system does not requi re adjust-
ment. Proper parki ng brake system adjustment i s
obtai ned by proper drum brake or drum-i n-hat brake
shoe adjustment. When servi ce i s needed, the l ever
auto-adjust mechani sm must be rel oaded and l ocked
out before servi ce can be performed.
The parki ng brake l ever has a short output cabl e
wi th an equal i zer bracket attached to i t that connects
to the parki ng brake cabl es (Fi g. 10). The output
cabl e can onl y be servi ced as part of the parki ng
brake l ever.
PARKING BRAKE CABLES
There i s an i ndi vi dual parki ng brake cabl e for each
rear wheel that joi ns a parki ng cabl e equal i zer,
attached to the parki ng brake l ever, to the rear park-
i ng brakes. The parki ng brake cabl es are made of
fl exi bl e steel cabl e. Both drum rear brakes and di sc
rear brakes use the same parki ng brake cabl e confi g-
urati on, but the cabl es are di fferent.
PARKING BRAKES
On vehi cl es equi pped wi th rear drum brakes, the
rear wheel servi ce brakes al so act as the vehi cl e’s
parki ng brakes. The rear drum brake shoes, when
acti ng as parki ng brakes, are mechani cal l y operated
usi ng an i nternal actuati ng l ever and strut connected
to the fl exi bl e steel parki ng brake cabl e.
The parki ng brakes on vehi cl es equi pped wi th rear
di sc brakes consi st of a smal l duo-servo brake assem-
bl y mounted to the di sc brake cal i per adapter (Fi g.
11). The hat (center) secti on of the rear brake rotor
serves as the braki ng surface (drum) for the parki ng
brakes (Fi g. 12). Thi s parki ng brake appl i cati on uses
the same operati ng cabl e confi gurati on as the drum
brake equi pped vehi cl es, but di fferent cabl es.
Fig. 10 Parking Brake Lever
1 – PARKING BRAKE LEVER
2 – PARKING BRAKE WARNING LAMP SWITCH
3 – OUTPUT CABLE
Fig. 11 Parking Brake Assembly With Rear Disc
Brakes
1 – DISC BRAKE ADAPTER
2 – PARKING BRAKE BRAKE SHOES
3 – HUB/BEARING ASSEMBLY
4 – BRAKING DISC STONE SHIELD
5 – PARKING BRAKE ACTUATING STRUT
PL BRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)
RED BRAKE WARNING LAMP
The red BRAKE warni ng l amp i s l ocated i n the
i nstrument panel cl uster and i l l umi nates when a l ow
brake fl ui d condi ti on occurs or when the parki ng
brake l ever i s appl i ed wi th the i gni ti on key i n the
ON posi ti on. I n addi ti on, the red BRAKE warni ng
l amp i l l umi nates when the i gni ti on swi tch i s moved
from the OFF to the ON or CRANK posi ti on. Thi s i s
done to check the bul b’s operati on.
Probl ems wi th thi s system wi l l general l y be of the
type where the warni ng l amp fai l s to turn on when i t
shoul d, or remai ns on when i t shoul d not.
The red BRAKE warni ng l amp LED i s suppl i ed
wi th current anyti me the i gni ti on swi tch i s ON. The
bul b i s i l l umi nated by compl eti ng the ground ci rcui t
usi ng any of the fol l owi ng components:
• the brake fl ui d l evel swi tch l ocated i n the mas-
ter cyl i nder reservoi r
• the parki ng brake swi tch mounted on the park-
i ng brake l ever (Fi g. 10)
• the i gni ti on swi tch when the i gni ti on swi tch i s
fi rst moved to the ON or CRANK posi ti on
• the mechani cal i nstrument cl uster (MI C) (wi th
ABS)
• the ABS el ectroni c brake di stri buti on (EBD)
The brake fl ui d l evel swi tch i s l ocated i n the brake
fl ui d reservoi r of the master cyl i nder assembl y (Fi g.
1). The purpose of the swi tch i s to provi de the dri ver
wi th an earl y warni ng that the brake fl ui d l evel i n
the master cyl i nder reservoi r has dropped bel ow an
acceptabl e l evel .
As the fl ui d drops bel ow the mi ni mum l evel , the
fl ui d l evel swi tch cl oses and grounds the red BRAKE
warni ng l amp ci rcui t. Thi s turns on the red BRAKE
warni ng l amp. At thi s ti me, the master cyl i nder fl ui d
reservoi r must be checked and fi l l ed to the ful l mark
wi th DOT 3 brake fl ui d. An abnormal l oss of brake
fl ui d i n the master cyl i nder fl ui d reservoi r coul d be
caused by a l eak i n the hydraul i c system. The enti re
brake hydraul i c system shoul d be checked for evi -
dence of a l eak.
The red BRAKE warni ng l amp can be turned on by
the MI C i n the case where the ABS i s experi enci ng a
probl em where the amber ABS warni ng l amp needs
to be i l l umi nated and cannot. The MI C wi l l then i l l u-
mi nate the red BRAKE warni ng l amp.
BRAKE LAMP SWITCH
The brake l amp swi tch i s l ocated under the i nstru-
ment panel , at the brake pedal arm (Fi g. 13). I t con-
trol s operati on of the vehi cl e’s stop l amps. Al so, i f the
vehi cl e i s equi pped wi th speed control , the brake
l amp swi tch wi l l deacti vate the speed control when
the brake pedal i s depressed.
When the brake pedal i s depressed, the brake l amp
swi tch contacts are cl osed, compl eti ng the ci rcui t to
the stop l amps, thus i l l umi nati ng the stop l amps and
the center-hi gh-mounted stop l amp (CHMSL).
Fig. 12 Drum-In-Hat Brake Rotor
1 – REAR BRAKING DISK ROTOR
2 – HAT SECTION OF REAR BRAKING DISC (PARKING BRAKE
BRAKING SURFACE)
Fig. 13 Brake Lamp Switch
1 – SWITCH
2 – CLIP
3 – BRAKE PEDAL
4 – CONNECTOR
5 - 8 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING LAMP,
BRAKE NOISE and OTHER BRAKE CONDITIONS.
RED BRAKE WARNING LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON
1. Parking brake lever not fully
released.
1. Release parking brake lever.
2. Parking brake warning lamp switch
on parking brake lever.
2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp
goes out, replace switch.
5. Mechanical instrument cluster (MIC)
problem.
5. Refer to Chassis Diagnostic Procedures
manual.
6. ABS EBD malfunction. 6. Refer to ABS section and Chassis
Diagnostic Procedures manual.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.
2. Lubricate brake caliper slides.
DISC BRAKE RATTLE OR
CLUNK
1. Broken or missing anti-rattle spring
clips on shoes.
1. Replace brake shoes.
2. Caliper guide pins loose. 2. Tighten guide pins.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)
1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.
1. Lubricate shoe contact areas on brake
shoe support plates.
2. Wheel cylinder out of alignment. 2. Loosen wheel cylinder mounting bolts,
realign wheel cylinder with brake shoes and
tighten mounting bolts.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.
1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN
1. Lack of lubricant on brake shoe
support plate where shoes ride and at
the anchor.
1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING
1. ABS wheel speed sensor or tone
wheel.
1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL).
1. Foreign object interference with
brakes.
1. Inspect brakes and remove foreign object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
PL BRAKES 5 - 9
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.
1. Isolate condition as rear or front.
Reface or replace brake drums or rotors
as necessary.
BRAKES DRAG (FRONT OR
ALL)
1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
BRAKES DRAG (REAR
ONLY)
1. Parking brake cables binding or
froze up.
1. Check cable routing. Replace cables as
necessary.
2. Parking brake cable return spring
not returning shoes.
2. Replace cables as necessary.
3. Service brakes not adjusted properly
(rear drum brakes only).
3. Follow the procedure listed in the
adjustment section.
4. Obstruction inside the center
console preventing full return of the
parking brake cables.
4. Remove console and remove
obstruction.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.
2. Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL
EFFORT
1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist. 2. Refer to power brake booster in the
diagnosis and testing section.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.
4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)
1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.
2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL
TRAVEL (PEDAL GOES TO
FLOOR - CAN’T SKID
WHEELS)
1. Power brake booster runout
(vacuum assist).
1. Check booster vacuum hose and
engine tune for adequate vacuum supply.
Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP DURING
HARD BRAKING)
1. One of the two hydraulic circuits to
the front brakes is malfunctioning.
1. Inspect system for leaks. Check master
cylinder for internal malfunction.
5 - 10 BRAKES PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
PEDAL PULSATES/SURGES
DURING BRAKING
1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.
1. Isolate condition as rear or front.
Reface or replace brake drums or rotors
as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).
2. Check booster vacuum hose and
engine tune for adequate vacuum supply.
Refer to power brake booster in the
diagnosis and testing section.
PREMATURE REAR WHEEL
LOCKUP
1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles only).
2. Test proportioning valves folowing
procedure listed in diagnosis and testing
section. Replace valves as necessary.
3. ABS EBD not functioning. 3. Refer to the ABS section and Chassis
Diagnostic Procedures manual.
4. Improper power brake booster
assist.
4. Refer to power brake booster in the
diagnosis and testing section.
STOP LAMPS STAY ON 1. Brake lamp switch out of
adjustment.
1. Adjust brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.
4. Replace power brake booster.
VEHICLE PULLS TO RIGHT
OR LEFT ON BRAKING
1. Frozen brake caliper piston. 1. Replace frozen piston or caliper. Bleed
brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL
1. Rear brakes out of adjustment. 1. Adjust rear drum brake shoes, or rear
parking brake shoes on vehicles with rear
disc brakes.
POWER BRAKE BOOSTER
BASIC TEST
(1) Wi th engi ne off, depress and rel ease the brake
pedal several ti mes to purge al l vacuum from the
power brake booster.
(2) Depress and hol d the pedal wi th l i ght effort (15
to 25 l bs. pressure), then start the engi ne.
The pedal shoul d fal l sl i ghtl y, then hol d. Less effort
shoul d be needed to appl y the pedal at thi s ti me. I f
the pedal fel l as i ndi cated, perform the VACUUM
LEAK TEST l i sted after the BASI C TEST. I f the
pedal di d not fal l , conti nue on wi th thi s BASI C
TEST.
(3) Di sconnect the vacuum hose on the si de of the
vacuum check val ve that l eads to the speed control ,
then connect a vacuum gauge to the open vacuum
port on the val ve.
(4) Start the engi ne.
(5) When the engi ne i s at warm operati ng temper-
ature, al l ow i t to i dl e and check the vacuum at the
gauge.
PL BRAKES 5 - 11
DIAGNOSIS AND TESTING (Continued)
I f the vacuum suppl y i s 12 i nches Hg (40.5 kPa) or
more, the power brake booster i s defecti ve and must
be repl aced. I f the vacuum suppl y i s bel ow 12 i nches,
conti nue on wi th thi s BASI C TEST.
(6) Shut off the engi ne.
(7) Connect the vacuum gauge to the vacuum ref-
erence port on the engi ne i ntake mani fol d.
(8) Start the engi ne and observe the vacuum gauge.
I f the vacuum i s sti l l l ow, check the engi ne tune
and repai r as necessary. I f the vacuum i s above 12
i nches, the hose or check to the booster has a restri c-
ti on or l eak.
Once an adequate vacuum suppl y i s obtai ned,
repeat the BASI C TEST.
VACUUM LEAK TEST
(1) Di sconnect the vacuum hose on the si de of the
power brake booster vacuum check val ve that l eads
to the speed control , then connect a vacuum gauge to
the open vacuum port on the val ve.
(2) Remove the remai ni ng hose on the vacuum
check val ve that i s not the vacuum suppl y hose com-
i ng from the i ntake mani fol d. Cap off the open port
on the check val ve.
(3) Start the engi ne.
(4) Al l ow the engi ne to warm up to normal operat-
i ng temperature and engi ne i dl e.
(5) Usi ng vacuum l i ne pl i ers, cl ose off the vacuum
suppl y hose near the booster and observe the vacuum
gauge.
I f the vacuum drop exceeds 1.0 i nch Hg (3.3 kPa)
i n one mi nute, repeat the above steps to confi rm the
readi ng. The vacuum l oss shoul d be l ess than 1.0
i nch Hg i n one mi nute ti me span. I f the l oss i s more
than 1.0 i nch Hg, repl ace the power brake booster. I f
i t i s not, conti nue on wi th thi s test.
(6) Remove the pl i ers from the hose temporari l y.
(7) Appl y l i ght effort (approxi matel y 15 l bs. of
force) to the brake pedal and hol d the pedal steady.
Do not move the pedal once the pressure i s appl i ed
or the test resul ts may vary.
(8) Have an assi stant reattach the pl i ers to the
vacuum suppl y hose.
(9) Al l ow 5 seconds for stabi l i zati on, then observe
the vacuum gauge.
I f the vacuum drop exceeds 3.0 i nches Hg (10 kPa)
i n 15 seconds, repeat the above steps to confi rm the
readi ng. The vacuum l oss shoul d be l ess than 3.0
i nches Hg i n 15 seconds ti me span. I f the l oss i s
more than 3.0 i nches Hg, repl ace the power brake
booster. I f i t i s not, the booster i s not defecti ve.
DRUM BRAKE AUTOMATIC ADJUSTER
To properl y test the drum brake automati c
adjuster, the ai de of a hel per i nsi de the vehi cl e to
appl y the brakes wi l l be necessary.
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the access pl ug from the rear adjust-
ment sl ot i n each brake support pl ate.
(3) I nsert a thi n screwdri ver i n the adjustment
sl ot and push back the adjustment l ever. Wi th the
l ever i n thi s posi ti on, back the star wheel adjustment
off approxi matel y 10 notches. Thi s wi l l el i mi nate the
possi bi l i ty that the brake i s at ful l adjustment, and
can be adjusted no further.
(4) Remove the screwdri ver from the adjustment sl ot.
(5) Watch the star wheel through the adjustment
sl ot, whi l e a hel per appl i es the brake pedal . As the
brake shoes appl y, the adjustment l ever shoul d move
downward, turni ng the star wheel . A defi ni te rotati on
of the adjuster star wheel can be observed i f the
automati c adjuster i s worki ng properl y.
I f the star wheel does not move as i ndi cated, the
brake drum needs to be removed and further i nspec-
ti on of the rear brakes i s necessary.
(6) I f the star wheel i s operati ng properl y, readjust
the brakes. Refer to ADJUSTMENTS i n thi s secti on
of thi s servi ce manual group.
(7) Rei nstal l the adjustment sl ot access pl ug.
(8) Lower the vehi cl e.
BRAKE ROTOR
Any servi ci ng of the rotor requi res extreme care to
mai ntai n the rotor wi thi n servi ce tol erances to
ensure proper brake acti on.
Excessi ve runout or wobbl e i n a rotor can i ncrease
pedal travel due to pi ston knock-back. Thi s i ncreases
gui de pi n sl eeve wear due to the tendency of the cal -
i per to fol l ow the rotor wobbl e.
When di agnosi ng a brake noi se or pul sati on, the
machi ned di sc braki ng surface shoul d be checked and
i nspected.
BRAKING SURFACE INSPECTION
Li ght braki ng surface scori ng and wear i s accept-
abl e. I f heavy scori ng or warpi ng i s evi dent, the rotor
must be refaced or repl aced. Refer to SERVI CE PRO-
CEDURES i n thi s secti on of thi s group for i nforma-
ti on on brake rotor machi ni ng.
Excessi ve wear and scori ng of the rotor can cause
i mproper l i ni ng contact on the rotor’s braki ng sur-
face. I f the ri dges on the rotor are not removed before
new brake shoes are i nstal l ed, i mproper wear of the
shoes wi l l resul t.
I f a vehi cl e has not been dri ven for a peri od of
ti me, the rotor’s braki ng surface wi l l rust i n the
areas not covered by the brake shoes at that ti me.
Once the vehi cl e i s dri ven, noi se and chatter from
the di sc brakes can resul t when the brakes are
appl i ed.
5 - 12 BRAKES PL
DIAGNOSIS AND TESTING (Continued)
Some di scol orati on or wear of the rotor surface i s
normal and does not requi re resurfaci ng when l i n-
i ngs are repl aced. I f cracks or burned spots are evi -
dent, the rotor must be repl aced.
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f i t i s worn
bel ow mi ni mum thi ckness or i f machi ni ng the rotor
wi l l cause i ts thi ckness to fal l bel ow speci fi cati ons.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Mi ni mum thi ckness speci fi cati ons are cast on the
rotor’s unmachi ned surface (Fi g. 14). Li mi ts can al so
be found i n the tabl e at the end of thi s brake rotor
i nformati on.
ROTOR THICKNESS VARIATION
Thi ckness vari ati on i n a rotor’s braki ng surface
can resul t i n pedal pul sati on, chatter and surge. Thi s
can al so be caused by excessi ve runout i n the rotor or
the hub.
Rotor thi ckness vari ati on measurements shoul d be
made i n conjuncti on wi th measuri ng runout. Mea-
sure thi ckness of the brake rotor at 12 equal poi nts
around the rotor braki ng surface wi th a mi crometer
at a radi us approxi matel y 25 mm (1 i nch) from edge
of rotor (Fi g. 15). I f thi ckness measurements vary by
more than 0.013 mm (0.0005 i nch), the rotor shoul d
refaced or repl aced. Refer to SERVI CE PROCE-
DURES i n thi s secti on of thi s group for i nformati on
on brake rotor machi ni ng.
ROTOR RUNOUT
On-vehi cl e rotor runout i s the combi nati on of the
i ndi vi dual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separabl e).
To measure rotor runout on the vehi cl e, fi rst remove
the ti re and wheel assembl y. Rei nstal l the wheel
mounti ng nuts on the studs, ti ghteni ng the rotor to
the hub. Mount the Di al I ndi cator, Speci al Tool
C-3339, wi th Mounti ng Adaptor, Speci al Tool SP- 1910
on steeri ng arm. The di al i ndi cator pl unger shoul d
contact braki ng surface of rotor approxi matel y one
i nch from edge of rotor (Fi g. 16). Check l ateral runout
on both si des of the rotor, marki ng the l ow and hi gh
spots on both. Runout l i mi ts can be found i n the tabl e
at the end of thi s brake rotor i nformati on.
I f runout i s i n excess of the speci fi cati on, check the
l ateral runout of the hub face. Before removi ng the
rotor from the hub, pl ace a chal k mark across both
the rotor and the one wheel stud cl osest to where the
hi gh runout measurement was taken. Thi s way, the
ori gi nal mounti ng spot of the rotor on the hub i s
i ndexed (Fi g. 17).
Remove the rotor from the hub.
NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an
accurate indicator reading.
Mount Di al I ndi cator, Speci al Tool C-3339, and
Mounti ng Adaptor, Speci al Tool SP-1910, to the steer-
i ng knuckl e. Posi ti on the i ndi cator stem so i t contacts
the hub face near the outer di ameter. Care must be
taken to posi ti on stem outsi de of the stud ci rcl e, but
i nsi de of the chamfer on the hub ri m (Fi g. 18).
Fig. 14 Minimum Brake Rotor Thickness Markings
(Typical)
1 – ROTOR MINIMUM THICKNESS MARKING
2 – ROTOR
Fig. 15 Checking Rotor For Thickness
1 – CALIPER
PL BRAKES 5 - 13
DIAGNOSIS AND TESTING (Continued)
Hub runout shoul d not exceed 0.08 mm (0.003
i nch). I f runout exceeds thi s speci fi cati on, the hub
must be repl aced. Refer to the SUSPENSI ON group
i n thi s servi ce manual for the repl acement procedure.
I f the hub runout does not exceed thi s speci fi ca-
ti on, i nstal l the rotor back on the hub, al i gni ng the
chal k marks on the rotor wi th a wheel mounti ng
stud, two studs apart from the ori gi nal stud (Fi g. 19).
Ti ghten nuts i n the proper sequence and torque to
speci fi cati ons.
Recheck brake rotor runout to see i f the runout i s
now wi thi n speci fi cati ons.
I f runout i s not wi thi n speci fi cati ons, reface or
repl ace the brake rotor. Refer to SERVI CE PROCE-
DURES i n thi s secti on of thi s group for i nformati on
on brake rotor machi ni ng.
Fig. 16 Checking Rotor Runout
1 – SPECIAL TOOL SP-1910
2 – 10 MILLIMETERS FROM EDGE
3 – DISC SURFACE
4 – SPECIAL TOOL C-3339
Fig. 17 Marking Rotor and Wheel Stud
1 – CHALK MARK
Fig. 18 Checking Hub Runout
1 – HUB SURFACE
2 – SPECIAL TOOL C-3339
3 – SPECIAL TOOL SP-1910
Fig. 19 Index Rotor And Wheel Stud
1 – CHALK MARK
5 - 14 BRAKES PL
DIAGNOSIS AND TESTING (Continued)
BRAKE ROTOR LIMITS
Braking Rotor Rotor Thickness
Minimum
Rotor
Thickness
Rotor
Thickness
Variation
Rotor
Runout*
Rotor Micro
Finish
Front Rotor
21.87–22.13 mm
0.861-0.871 in.
20.4 mm
0.803 in.
0.013 mm
0.0005 in.
0.13 mm
0.005 in.
15-80 RMS
Rear Rotor
8.75–9.25 mm
0.344 -0.364 in.
7.25 mm
0.285 in.
0.013 mm
0.0005 in.
0.13 mm
0.005 in.
15-80 RMS
* TIR Total Indicator Reading (Measured On Vehicle)
BRAKE DRUM
Wi th the drum off the vehi cl e, measure the drum
for di ameter vari ati on (oval shape). The di ameter
vari ati on of the drum braki ng surface must not
exceed ei ther 0.0635 mm (0.0025 i nch) i n 30° or
0.0889 mm (0.0035 i nch) i n 360°.
Measure brake drum runout. Brake drum runout
shoul d be checked wi th the drum mounted on a
brake l athe. Brake drum runout shoul d not exceed
0.1524 mm (0.006 i nch).
I f ei ther of these measurements are not wi thi n
speci fi cati on, reface or repl ace the drum. Refer to
BRAKE DRUM MACHI NI NG i n the SERVI CE PRO-
CEDURES secti on of thi s servi ce manual group for
refaci ng procedures.
Al ways repl ace the drum i f machi ni ng wi l l cause
the di ameter to exceed drum maxi mum di ameter. Al l
brake drums are marked wi th the maxi mum al l ow-
abl e brake drum di ameter (Fi g. 20).
PROPORTIONING VALVE
I f premature rear wheel ski d occurs on a hard
brake appl i cati on, i t coul d be an i ndi cati on that a
mal functi on has occurred wi th one of the proporti on-
i ng val ves.
One proporti oni ng val ve control s the ri ght rear
brake, and the other proporti oni ng val ve control s the
l eft rear brake (Fi g. 21). Therefore, a road test to
determi ne whi ch rear brake ski ds fi rst i s essenti al .
Before testi ng the proporti oni ng val ve i n questi on,
i nspect the rear brake l i ni ngs for contami nati on or
for repl acement shoes not meeti ng the OEM brake
l i ni ng materi al speci fi cati ons.
The proporti oni ng val ve shoul d al ways be tested
pri or to bei ng repl aced.
Fig. 20 Brake Drum Maximum Diameter
Identification
1 – HUB/BEARING ASSEMBLY
2 – WHEEL MOUNTING STUDS
3 – BRAKE DRUM MAXIMUM DIAMETER MARKING
4 – REAR BRAKE DRUM
Fig. 21 Proportioning Valve Location
1 – RIGHT FRONT BRAKE TUBE
2 – LEFT FRONT BRAKE TUBE
3 – LEFT REAR BRAKE TUBE
4 – REAR PROPORTIONING VALVES
5 – RIGHT REAR BRAKE TUBE
PL BRAKES 5 - 15
DIAGNOSIS AND TESTING (Continued)
The i n-l i ne proporti oni ng val ves used on thi s vehi -
cl e requi re speci al pressure fi tti ngs to test the pro-
porti oni ng val ves for proper proporti oni ng val ve
functi on. The pressure fi tti ngs are i nstal l ed before
and after the proporti oni ng val ve bei ng tested to ver-
i fy proporti oni ng val ve i s mai ntai ni ng the requi red
hydraul i c pressure to the rear wheel brake whi ch i t
control s.
The testi ng of proporti oni ng val ves for thi s vehi cl e,
i f equi pped wi th ABS, can be found i n the
ANTI LOCK BRAKE SYSTEM secti on.
PROPORTIONING VALVE TEST
The test procedure i s the same for ei ther rear pro-
porti oni ng val ve. After road testi ng the vehi cl e to
determi ne whi ch wheel ski ds fi rst, fol l ow the proce-
dure bel ow for testi ng the suspect proporti oni ng
val ve.
(1) Usi ng a brake pedal hol di ng tool as shown (Fi g.
22), depress the brake pedal past i ts fi rst one i nch of
travel and hol d i t i n thi s posi ti on. Thi s wi l l i sol ate
the master cyl i nder from the brake hydraul i c system
and wi l l not al l ow the brake fl ui d to drai n out of the
master cyl i nder reservoi r.
(2) Use the fi gure shown to determi ne whi ch pro-
porti oni ng val ve needs to be tested (Fi g. 21).
(3) Remove the hydraul i c brake tube from the pro-
porti oni ng val ve control l i ng the rear wheel of the
vehi cl e that has premature wheel ski d.
(4) Remove the proporti oni ng val ve from i ts outl et
port on the master cyl i nder.
CAUTION: Be sure the pressure test fittings being
installed into master cylinder and proportioning
valve, have the correct thread sizes needed.
(5) I nstal l the Brake Pressure Adapters, Speci al
Tool 8644 and 6805-3 onto the proporti oni ng val ve
(Fi g. 23).
(6) I nstal l the proporti oni ng val ve (wi th tool s) back
i nto the outl et port on the master cyl i nder.
(7) Attach a Pressure Gauge, Speci al Tool
C-4007-A, to each pressure adapter (Fi g. 24).
(8) Remove the brake pedal hol di ng tool . Bl eed any
ai r out of the pressure gauge hoses at the pressure
gauge.
(9) Wi th the ai d of a hel per, appl y pressure to the
brake pedal unti l the readi ng on proporti oni ng val ve
i nl et gauge i s at the target i nl et pressure shown i n
the BRAKE PROPORTI ONI NG VALVE APPLI CA-
TI ONS AND PRESSURE SPECI FI CATI ONS tabl e
Fig. 22 Brake Pedal Holding Tool
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 23 Tools On Valve
1 – PROPORTIONING VALVE
Fig. 24 Pressure Gauge Set
1 – SPECIAL TOOL C-4007–A
5 - 16 BRAKES PL
DIAGNOSIS AND TESTING (Continued)
fol l owi ng thi s procedure. I f the i nl et gauge pressure
overshoots i ts target pressure when the pedal i s
depressed, rel ease the brake pedal , rel i evi ng the
pressure i n the system, before reappl yi ng the pedal
to reach the target pressure at the i nl et gauge. Thi s
i s necessary to get an accurate readi ng of the outl et
pressure.
(10) Once i nl et pressure has been achi eved, check
the pressure readi ng on the proporti oni ng val ve out-
l et gauge. I f the proporti oni ng val ve outl et pressure
does not agree wi th val ue shown i n the tabl e, repl ace
the proporti oni ng val ve. I f proporti oni ng val ve i s
wi thi n pressure speci fi cati ons, the val ve i s good and
does not requi re repl acement.
(11) Rei nstal l the brake hol di ng tool on the brake
pedal and remove the test equi pment from the vehi cl e.
(12) Remove the tool s from the proporti oni ng
val ve.
(13) I nstal l the proporti oni ng val ve i n the master
cyl i nder and hand ti ghten unti l the proporti oni ng
val ve i s ful l y i nstal l ed and i ts O-ri ng seal i s seated
i nto the master cyl i nder. Torque the proporti oni ng
val ve to 40 N·m (30 ft. l bs.).
(14) I nstal l the brake tube on the proporti oni ng
val ve. Torque the tube nut to 17 N·m (145 i n. l bs.).
(15) Bl eed the affected brake l i ne. See BASE
BRAKE BLEEDI NG i n thi s secti on of thi s servi ce
manual group.
BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS
Sales
Code
Brake System Type Split Point Slope Identification
Inlet
Pressure
Outlet Pressure
BRA 14” Disc/Drum 300 psi 0.34 Black Band 1000 psi 550-650 psi
BRD 14” Disc/Disc 400 psi 0.43 Bar Code Band 1000 psi 600-700 psi
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts. Swel l i ng i ndi cates the
presence of petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f the fl ui d sep-
arates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f the brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush the brake system. Repl ace al l the rubber
parts or components contai ni ng rubber comi ng i nto
contact wi th the brake fl ui d i ncl udi ng: the master
cyl i nder; proporti oni ng val ves; cal i per seal s; wheel
cyl i nder seal s; ABS hydraul i c control uni t; and al l
hydraul i c fl ui d hoses.
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING
Brake fl ui d l evel shoul d be checked a mi ni mum of
twi ce a year.
Master cyl i nder reservoi rs are marked, FULL and
MI N, i ndi cati ng the al l owabl e brake fl ui d l evel range
i n the master cyl i nder brake fl ui d reservoi r (Fi g. 25).
CAUTION: Use only Moparா brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
Al though there i s a range, the preferred l evel i s
FULL. I f necessary, adjust the brake fl ui d l evel to
the FULL mark on the si de of the master cyl i nder
brake fl ui d reservoi r.
BASE BRAKE BLEEDING
NOTE: For bleeding the ABS hydraulic system,
refer to ANTILOCK BRAKE SYSTEM BLEEDING in
the ANTILOCK BRAKE SYSTEM section of this ser-
vice manual group.
Fig. 25 Master Cylinder
1 – POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 – POWER BRAKE BOOSTER
3 – BRAKE FLUID PRESSURE SWITCH
4 – MASTER CYLINDER
PL BRAKES 5 - 17
DIAGNOSIS AND TESTING (Continued)
CAUTION: Before removing the master cylinder
cap, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder res-
ervoir.
CAUTION: Use only Moparா brake fluid or an equiv-
alent from a fresh, tightly sealed container. Brake
fluid must conform to DOT 3 specifications.
Do not pump the brake pedal at any ti me whi l e
havi ng a bl eeder screw open duri ng the bl eedi ng pro-
cess. Thi s wi l l onl y i ncrease the amount of ai r i n the
system and make addi ti onal bl eedi ng necessary.
Do not al l ow the master cyl i nder reservoi r to run
out of brake fl ui d whi l e bl eedi ng the system. An
empty reservoi r wi l l al l ow addi ti onal ai r i nto the
brake system. Check the fl ui d l evel frequentl y and
add fl ui d as needed.
The fol l owi ng wheel ci rcui t sequence for bl eedi ng
the brake hydraul i c system shoul d be used to ensure
adequate removal of al l trapped ai r from the hydrau-
l i c system.
• Left rear wheel
• Ri ght front wheel
• Ri ght rear wheel
• Left front wheel
MANUAL BLEEDING
NOTE: To bleed the brakes manually, the aid of a
helper will be required.
(1) Attach a cl ear pl asti c hose to the bl eeder screw
and feed the hose i nto a cl ear jar contai ni ng enough
fresh brake fl ui d to submerge the end of the hose
(Fi g. 26).
(2) Have a hel per pump the brake pedal three or
four ti mes and hol d i t i n the down posi ti on.
(3) Wi th the pedal i n the down posi ti on, open the
bl eeder screw at l east 1 ful l turn.
(4) Once the brake pedal has dropped, cl ose the
bl eeder screw. After the bl eeder screw i s cl osed,
rel ease the brake pedal .
(5) Repeat the above steps unti l al l trapped ai r i s
removed from that wheel ci rcui t (usual l y four or fi ve
ti mes).
(6) Bl eed the remai ni ng wheel ci rcui ts i n the same
manner unti l al l ai r i s removed from the brake sys-
tem. Moni tor the fl ui d l evel i n the master cyl i nder
reservoi r to make sure i t does not go dry.
(7) Check the brake pedal travel . I f pedal travel i s
excessi ve or has not been i mproved, some ai r may
sti l l be trapped i n the system. Rebl eed the brakes as
necessary.
(8) Test dri ve the vehi cl e to veri fy the brakes are
operati ng properl y and pedal feel i s correct.
PRESSURE BLEEDING
NOTE: Follow pressure bleeder manufacturer’s
instructions for use of pressure bleeding equip-
ment.
Fol l owi ng the same wheel ci rcui t sequence as pre-
scri bed for manual bl eedi ng.
(1) Attach Adapter, Speci al Tool 6921, to the mas-
ter cyl i nder reservoi r (Fi g. 27).
Fig. 26 Proper Method for Purging Air From Brake
System (Typical)
1 – CLEAR HOSE
2 – BRAKE CALIPER
3 – BLEEDER SCREW
4 – CLEAN BRAKE FLUID
Fig. 27 Special Tool 6921
1 – MASTER CYLINDER
5 - 18 BRAKES PL
SERVICE PROCEDURES (Continued)
(2) Attach Bl eeder Tank, Speci al Tool C-3496-B, or
an equi val ent, to the adapter on the master cyl i nder.
(3) Attach a cl ear pl asti c hose to the bl eeder screw
and feed the hose i nto a cl ear jar contai ni ng enough
fresh brake fl ui d to submerge the end of the hose
(Fi g. 26).
(4) Open the bl eeder screw at l east one ful l turn or
more to obtai n a steady stream of brake fl ui d.
(5) After approxi matel y 4–8 ounces of fl ui d have
been bl ed through the brake ci rcui t and an ai r-free
fl ow i s mai ntai ned i n the cl ear pl asti c hose and jar,
cl ose the bl eeder screw.
(6) Repeat thi s procedure at al l the remai ni ng
bl eeder screws.
(7) Check the brake pedal travel . I f pedal travel i s
excessi ve or has not been i mproved, some ai r may
sti l l be trapped i n the system. Rebl eed the brakes as
necessary.
(8) Test dri ve the vehi cl e to veri fy the brakes are
operati ng properl y and pedal feel i s correct.
MASTER CYLINDER BLEEDING
(1) Cl amp the master cyl i nder i n a vi se.
(2) Attach four Master Cyl i nder Bl eed Tubes, Spe-
ci al Tool 8358-1, to the four ports of the master cyl -
i nder and ti ghten each i n pl ace (Fi g. 28). The bl eed
tubes for the ports pertai ni ng to the rear brakes are
made to attach to the proporti oni ng val ves screwed
i nto the master cyl i nder. Posi ti on the other end of
the tubes i nto the master cyl i nder reservoi r so thei r
outl ets are bel ow the surface of the brake fl ui d i n the
reservoi r when fi l l ed.
(3) Fi l l the brake fl ui d reservoi r wi th Mopar௡
brake fl ui d, or an equi val ent conformi ng to DOT 3
speci fi cati ons.
(4) Usi ng a wooden dowel as a pushrod (Fi g. 28),
press the pi stons i nward sl owl y appl yi ng brake pres-
sure, then rel ease the pressure, al l owi ng the pi stons
to return to the rel eased posi ti on. Repeat thi s several
ti mes unti l al l ai r bubbl es are expel l ed out of the
tubes and master cyl i nder bore.
(5) Remove the bl eed tubes from the master cyl i n-
der and pl ug the outl et ports.
(6) I nstal l the fi l l cap on the reservoi r.
(7) Remove the master cyl i nder from the vi se.
NOTE: It is not necessary to bleed the entire
hydraulic system after replacing just the master cyl-
inder unless the brake system has been open to air
for an excessive amount of time or air is present in
the lines. Only the master cylinder must be bled
and filled.
BRAKE TUBE REPAIR
Use onl y doubl e wal l 4.75 mm (3/16 i n.) steel tub-
i ng wi th Nygal coati ng for hydraul i c brake tube
repl acement. Nygal i s nyl on coated gal vani zed steel
tubi ng.
Care must be taken when repai ri ng brake tubi ng
to avoi d ki nki ng the tube. Use the proper bendi ng
and fl ari ng tool s. Do not route the tubes agai nst
sharp edges, movi ng components, or i nto hot areas.
Al l tubes shoul d be attached wi th the recommended
retai ni ng cl i ps.
PREPARING THE BRAKE TUBE FOR FLARING
(1) Use Tubi ng Cutter, Speci al Tool C-3478-A, or
an equi val ent to cut off the damaged fl are or tubi ng
(Fi g. 29).
(2) Make the ends of the tubi ng to be repai red
square (Fi g. 30) to ensure better seati ng of the fl ared
end tubi ng.
(3) Ream out any burrs or rough edges showi ng on
the i nsi de of the tubi ng to be fl ared (Fi g. 30).
(4) Stri p back enough of the nyl on coati ng at the
end of the l ength of tubi ng that wi l l fl ared so i t wi l l
not be i n the fl are i tsel f. At l east 5 mm shoul d be
removed.
NOTE: Place a tube nut on the tubing before flaring
it. It cannot be done after the tube is flared.
Fig. 28 Bleeding Master Cylinder
1 – WOODEN DOWEL
2 – MASTER CYLINDER
PL BRAKES 5 - 19
SERVICE PROCEDURES (Continued)
DOUBLE INVERTED TUBING FLARES
After prepari ng the tubi ng usi ng the procedure i n
PREPARI NG THE BRAKE TUBE FOR FLARI NG,
make a doubl e i nverted tubi ng fl are usi ng the fol l ow-
i ng procedure (Fi g. 31).
CAUTION: When using brake tubing with Nygal
coating, always use flare nuts designed for this
coating. They have a larger hole in the center to
accommodate the coating on the tube.
(1) I nstal l the repl acement fl are nut on the tube so
the threads are faci ng the fl are yet to be made (Fi g.
32).
(2) Open the Fl ari ng Tool , Speci al Tool C-4047 (or
an equi val ent), separati ng the tool s verti cal posts.
(3) Pl ace the tubi ng i n the jawed hol e between the
two verti cal posts.
(4) Sl owl y bri ng the verti cal posts together captur-
i ng the tube between the hal ves. Leave enough tub-
i ng sti cki ng through the top of the verti cal posts to
al l ow for fl ari ng. Appl y onl y enough pressure to hol d
the tube i n pl ace.
Fig. 29 Cutting And Flaring Of Brake Fluid Tubing
Fig. 30 Brake Fluid Tube Preparation For Flaring
1 – BE SURE ALL BURRS ARE REMOVED FROM INSIDE OF
TUBING
2 – BE SURE END OF TUBING IS SQUARE BEFORE FLARING
TUBE
3 – HYDRAULIC BRAKE LINE TUBING
Fig. 31 Double Inverted Brake Line Tubing Flare
1 – DOUBLE INVERTED-STYLE FLARE
Fig. 32 Double Wall Inverted Flare Connection
1 – INVERTED FLARE TUBE NUT
2 – SEAT
3 – INVERTED DOUBLE FLARE
4 – TUBE
5 - 20 BRAKES PL
SERVICE PROCEDURES (Continued)
(5) Pl ace the gauge (From A) over the end of the
brake tube. Adjust the tube hei ght i n the tool ’s jaws
unti l the end of the tube contacts the recessed notch
i n the gauge that matches the tubi ng si ze. Squeeze
the handl es of the fl ari ng tool , l ocki ng the tubi ng i n
pl ace. Remove the gauge.
(6) Pl ace the 3/16 i nch pl ug gauge (A) down i nto
the end of the tube. Ti ghten the fl ari ng handl e, push-
i ng the gauge i nto the tube unti l the gauge contacts
the verti cal posts of the tool .
(7) Rel ease the fl ari ng handl e and remove the pl ug
gauge from the parti al l y fl ared tube.
(8) Ti ghten the fl ari ng handl e down once more
unti l the tool s fl ari ng ti p has fi rml y seated the tube
to the verti cal posts, thus compl eti ng the fl are.
CAUTION: When inspecting the flare, make sure no
tubing nygal coating has been involved in the flare.
(9) Remove the fl ared tube from the fl ari ng tool
and i nspect the fl are to make sure i t i s uni form.
BRAKE ROTOR MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servi ci ng of the rotor requi res extreme care to
mai ntai n the rotor wi thi n servi ce tol erances to
ensure proper brake acti on.
I f the rotor surface i s deepl y scored or warped, or
there i s a compl ai nt of brake roughness or brake
pedal pul sati on, the rotor shoul d be refaced usi ng a
hub-mounted on-car brake l athe (Fi g. 33), or
repl aced.
The use of a hub-mounted on-car brake l athe i s
hi ghl y recommended to el i mi nate the possi bi l i ty of
excessi ve runout. I t trues the brake rotor to the vehi -
cl e’s hub and beari ng.
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 34).
Mi ni mum al l owabl e thi ckness i s the mi ni mum
thi ckness whi ch the brake rotor machi ned surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before i nstal l ati on, veri fy the brake rotor face and
the hub adapters are free of any chi ps, rust, or con-
tami nati on.
When mounti ng and usi ng the brake l athe, stri ct
attenti on to the brake l athe manufacturer’s operati ng
i nstructi ons i s requi red.
Machi ne both si des of the brake rotor at the same
ti me. Cutti ng both si des at the same ti me mi ni mi zes
the possi bi l i ty of a tapered or uneven cut.
SPECIFICATIONS AND LIMITS
When refaci ng a rotor, the requi red TI R (Total
I ndi cator Readi ng) and thi ckness vari ati on l i mi ts
MUST BE MAI NTAI NED. Extreme care i n the oper-
ati on of rotor turni ng equi pment i s requi red.
Fig. 33 On-Car Brake Lathe
1 – ON-CAR BRAKE LATHE
Fig. 34 Minimum Brake Rotor Thickness Markings
(Typical)
1 – ROTOR MINIMUM THICKNESS MARKING
2 – ROTOR
PL BRAKES 5 - 21
SERVICE PROCEDURES (Continued)
BRAKE ROTOR LIMITS
Braking Rotor Rotor Thickness
Minimum
Rotor
Thickness
Rotor
Thickness
Variation
Rotor Run
Out*
Rotor Micro
Finish
Front Rotor
21.87–22.13 mm
0.861-0.871 in.
20.4 mm
0.803 in.
0.013 mm
0.0005 in.
0.08 mm
0.003 in.
15-80 RMS
Rear Rotor
8.75–9.25 mm
0.344 -0.364 in.
7.25 mm
0.285 in.
0.013 mm
0.0005 in.
0.08 mm
0.003 in.
15-80 RMS
* TIR Total Indicator Reading (Measured On Vehicle)
BRAKE DRUM MACHINING
I f a brake drum i s deepl y scored or warped, i t can
be machi ned on a brake l athe equi pped to machi ne
brake drums. Fol l ow the manufacturers i nstructi ons
on the machi ni ng procedure.
Measure the brake drum di ameter before machi n-
i ng. I f machi ni ng the drum wi l l cause the drum to
exceed maxi mum al l owabl e di ameter, do not machi ne
the brake drum. I t needs to be repl aced.
CAUTION: Do not machine the brake drum if it will
cause the drum to exceed maximum allowable
diameter.
Al l brake drums are marked wi th the maxi mum
al l owabl e brake drum di ameter (Fi g. 35).
When machi ni ng, make sure the fi nal fi ni sh feed
cut i s fi ne i n order to avoi d a screw effect on the
brake shoes when the brakes are appl i ed. Thi s fi nal
feed cut speci fi cati on vari es from l athe manufacturer
to l athe manufacturer.
PARKING BRAKE AUTOMATIC ADJUSTER LOCK
OUT
WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARKING
BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY.
ADJUSTER LOADING AND LOCKING OUT
(1) Bl ock the ti re and wheel s so the vehi cl e does
not move once the vehi cl e parki ng brake l ever i s
rel eased.
(2) Ful l y appl y the parki ng brake l ever, then shi ft
the transmi ssi on i nto neutral .
(3) Remove the screws attachi ng the center con-
sol e, then remove the center consol e.
(4) Lower the parki ng brake l ever handl e to the
rel eased posi ti on.
(5) Grasp the parki ng brake l ever output cabl e by
hand and pul l upward. Conti nue pul l i ng on the cabl e
unti l a pi n punch can be i nserted through the hol e i n
the l ever mechani sm sector gear and the hol e i n the
ri ght si de of i ts mounti ng bracket (Fi g. 36). Thi s wi l l
l ock the parki ng brake automati c adjustment mecha-
ni sm i n pl ace and take tensi on off the parki ng brake
cabl es.
Fig. 35 Brake Drum Maximum Diameter
Identification
1 – HUB/BEARING ASSEMBLY
2 – WHEEL MOUNTING STUDS
3 – BRAKE DRUM MAXIMUM DIAMETER MARKING
4 – REAR BRAKE DRUM
5 - 22 BRAKES PL
SERVICE PROCEDURES (Continued)
ADJUSTER UNLOADING (UNLOCKING)
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster locking pin or pin punch.
(1) Be sure the rear parki ng brake cabl es are both
properl y i nstal l ed i n the equal i zer.
(2) Keepi ng your hands cl ear of the automati c
adjuster sector and pawl area, fi rml y grasp the park-
i ng brake l ever pi n punch (or l ocki ng pi n i f a new
mechani sm has been i nstal l ed) (Fi g. 36), then qui ckl y
remove i t from the parki ng brake l ever mechani sm.
Thi s wi l l al l ow the park brake l ever mechani sm to
automati cal l y adjust the parki ng brake cabl es.
(3) Cycl e the parki ng brake l ever once to posi ti on
the parki ng brake cabl es, then return the parki ng
brake l ever i ts rel eased posi ti on.
(4) Check the rear wheel s of the vehi cl e. They
shoul d rotate freel y wi thout draggi ng wi th the l ever
i n i ts rel eased posi ti on.
(5) Ful l y appl y the parki ng brake l ever.
(6) I nstal l the center consol e and i ts mounti ng
screws.
(7) Remove the bl ocks from the ti re and wheel s.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE SHOE LININGS ARE MADE FROM ASBES-
TOS-FREE MATERIALS, SOME AFTERMARKET
BRAKE SHOE LININGS MAY CONTAIN ASBESTOS.
THIS SHOULD BE TAKEN INTO ACCOUNT WHEN
SERVICING A VEHICLE’S BRAKE SYSTEM. IT IS
POSSIBLE THAT AFTERMARKET BRAKE SHOES
MAY HAVE BEEN INSTALLED ON THE VEHICLE.
ALWAYS WEAR A RESPIRATOR WHEN CLEANING
BRAKE COMPONENTS; ASBESTOS CAN CAUSE
SERIOUS BODILY HARM SUCH AS ASBESTOSIS
AND CANCER. NEVER CLEAN BRAKE COMPO-
NENTS BY USING COMPRESSED AIR; USE ONLY A
VACUUM CLEANER SPECIFICALLY DESIGNED FOR
THE REMOVAL OF BRAKE DUST. IF A VACUUM
CLEANER IS NOT AVAILABLE, CLEAN BRAKE
PARTS USING ONLY WATER-DAMPENED SHOP
TOWELS. DO NOT CREATE BRAKE LINING DUST
BY SANDING THE BRAKE LININGS WHEN SERVIC-
ING A VEHICLE. DISPOSE OF ALL DUST AND DIRT
SUSPECTED OF CONTAINING ASBESTOS FIBERS.
USE ONLY SEALED AIRTIGHT BAGS OR CONTAIN-
ERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL PROTECTION AGENCY
(EPA), FOR HANDLING AND DISPOSING OF PROD-
UCTS CONTAINING ASBESTOS.
CAUTION: Use only Moparா brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash it off immediately with water.
CAUTION: During service procedures, grease or
any other foreign material must be kept off the cal-
iper assembly, surfaces of the brake rotor and
external surfaces of the hub. Avoid deformation,
scratching or nicking of the brake rotor and brake
shoe linings.
Fig. 36 Pin Punch Installed
1 – PARKING BRAKE LEVER
2 – PIN PUNCH
3 – OUTPUT CABLE
PL BRAKES 5 - 23
SERVICE PROCEDURES (Continued)
BRAKE PEDAL
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
WITH AUTOMATIC TRANSAXLE
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e from i ts post on the battery.
(2) Pl ace the steeri ng wheel and ti res i n the
STRAI GHT-AHEAD posi ti on. Usi ng a steeri ng wheel
hol der, l ock the steeri ng wheel i n pl ace to keep i t
from rotati ng (Fi g. 37). Thi s keeps the cl ockspri ng i n
the proper ori entati on.
(3) Remove the steeri ng col umn coupl i ng retai ner
pi n, back off the pi nch bol t nut, and remove the
steeri ng col umn coupl i ng pi nch bol t (Fi g. 38) (the
pi nch bol t nut i s caged to the coupl i ng and i s not
removabl e). Separate the upper and l ower steeri ng
col umn coupl i ngs.
(4) Depress and hol d the brake pedal whi l e rotat-
i ng the brake l amp swi tch (Fi g. 39) i n a countercl ock-
wi se di recti on approxi matel y 30 degrees.
(5) Pul l the swi tch rearward and remove i t from
i ts mounti ng bracket.
(6) Remove the cl i p securi ng the power brake
booster i nput rod to the brake pedal (Fi g. 39).
Remove the i nput rod from the brake pedal .
(7) Remove the two upper nuts fasteni ng the brake
pedal bracket to the power brake booster (Fi g. 40).
(8) Careful l y pry the ti e bar runni ng between the
two upper booster mounti ng studs from i ts pl asti c
retai ni ng fasteners.
(9) Remove the two remai ni ng nuts fasteni ng the
brake pedal bracket to the power brake booster (Fi g.
40).
Fig. 37 Steering Wheel Holder
1 – STEERING WHEEL
2 – STEERING WHEEL HOLDER
3 – DRIVERS SEAT
Fig. 38 Steering Column Couplings
1 – STEERING COLUMN UPPER COUPLING
2 – PINCH BOLT
3 – STEERING COLUMN LOWER COUPLING
4 – BRAKE PEDAL
5 – NUT
6 – RETAINER PIN
Fig. 39 Brake Lamp Switch
1 – SWITCH
2 – CLIP
3 – BRAKE PEDAL
4 – CONNECTOR
5 - 24 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(10) I f the vehi cl e i s equi pped wi th anti l ock
brakes, careful l y push the power brake booster for-
ward unti l the booster contacts the ABS I CU mount-
i ng bracket.
(11) I f the vehi cl e does not have anti l ock brakes,
careful l y push the power brake booster forward one
to two i nches bei ng careful not to stretch the brake
l i nes from the master cyl i nder to the brakes.
(12) Remove the two nuts fasteni ng the brake
pedal bracket to the i nstrument panel support (Fi g.
40).
(13) Careful l y remove the brake pedal assembl y by
pul l i ng the pedal bracket back toward the i nstru-
ment panel , rel easi ng the bracket from the booster
studs. Next, ti p the bracket down past the i nput rod,
gui di ng the rod through the gap l eft by the mi ssi ng
brace removed i n Step (8). Remove the brake pedal
assembl y out from under the i nstrument panel .
(14) The pedal can be removed from i t’s bracket by
gri ndi ng off the peened end of the shaft, removi ng
the shaft, pedal and bushi ngs. A servi ce parts pack-
age i s avai l abl e to repl ace these i tems.
INSTALLATION
(1) I f the pedal has been removed from i t’s
bracket, i nstal l the pedal , bushi ngs and bol t-i n-shaft
on the bracket usi ng the avai l abl e servi ce parts pack-
age.
(2) I nstal l the brake pedal assembl y by ti ppi ng the
pedal bracket and gui di ng the power brake booster
mounti ng porti on up past the booster i nput rod.
Gui de the top of the bracket onto the studs protrud-
i ng from the i nstrument panel support (Fi g. 40), then
gui de the booster mounti ng porti on onto the power
brake booster mounti ng studs.
(3) Push the power brake booster back i nto mount-
i ng posi ti on from under the hood.
(4) I nstal l the two nuts fasteni ng the brake pedal
bracket to the i nstrument panel support (Fi g. 40).
I nstal l the nuts al l the way, but do not ti ghten them
at thi s ti me.
(5) I nstal l the two l ower power brake booster
mounti ng nuts, but do not ti ghten them at thi s ti me.
(6) Pl ace the ti e bar runni ng between the two
upper booster mounti ng studs onto the studs wi th
the l ong fl at si de faci ng upward and the curved si de
downward.
(7) I nstal l the two upper power brake booster
mounti ng nuts on thei r studs.
(8) Ti ghten al l four nuts fasteni ng the brake pedal
bracket to the power brake booster to a torque of 34
N·m (300 i n. l bs.).
(9) Ti ghten the two nuts fasteni ng the brake pedal
bracket to the i nstrument panel support to a torque
of 34 N·m (300 i n. l bs.).
(10) I nstal l the power brake booster i nput rod on
the pi n mounted on the si de of the brake pedal .
I nstal l a new retai ni ng cl i p on the end of the pi n
(Fi g. 39). Do not reuse the ol d cl i p.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it’s fully extended posi-
tion.
(11) Hol d the brake l amp swi tch fi rml y i n one
hand. Then usi ng the other hand, pul l outward on
the pl unger of the brake l amp swi tch unti l i t has
ratcheted out to i ts ful l y extended posi ti on.
(12) Mount the brake l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure:
• Depress the brake pedal as far down as possi bl e.
• I nstal l the swi tch i n i ts bracket by al i gni ng the
i ndex tab on the swi tch wi th the sl ot i n the mounti ng
bracket.
• When the swi tch i s ful l y seated i n i ts bracket,
rotate the swi tch cl ockwi se approxi matel y 30° to l ock
the swi tch i nto pl ace.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(13) Gentl y pul l back on the brake pedal unti l the
pedal stops movi ng. Thi s wi l l ratchet the swi tch
pl unger backward to the correct adjustment posi ti on.
(14) I nstal l the dash-to-l ower coupl i ng seal i n
pl ace over the l ower coupl i ng’s pl asti c col l ar and
dash cover.
(15) Veri fy the front ti res are sti l l i n the
STRAI GHT-AHEAD posi ti on.
Fig. 40 Brake Pedal Mounting
1 – CLUTCH CABLE
2 – BOOSTER MOUNTING NUTS
3 – UPPER MOUNTING NUTS
PL BRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)
(16) Reconnect the steeri ng col umn l ower coupl i ng
to the steeri ng col umn upper coupl i ng (Fi g. 38).
I nstal l the coupl i ng pi nch bol t an ti ghten the pi nch
bol t nut to a torque of 28 N·m (250 i n. l bs.). I nstal l
the pi nch bol t retai ner pi n.
(17) Remove the steeri ng wheel hol der (Fi g. 37).
(18) Whi l e l ooki ng under the i nstrument panel at
the l ower coupl i ng, rotate the steeri ng wheel back-
and-forth to veri fy that the l ower coupl i ng does not
squeak agai nst the dash-to-coupl i ng seal .
(19) Reconnect the battery negati ve termi nal .
(20) Check the stop l amps to veri fy they are oper-
ati ng properl y and not stayi ng on when the pedal i s
i n the rel eased posi ti on.
(21) Road test the vehi cl e to ensure proper opera-
ti on of the brakes.
WITH MANUAL TRANSAXLE
REMOVAL
(1) Remove the i nstrument panel . Refer to the
I NSTRUMENT PANELS AND SYSTEMS group i n
thi s servi ce manual for the requi red procedure.
(2) Depress and hol d the brake pedal whi l e rotat-
i ng the brake l amp swi tch (Fi g. 39) i n a countercl ock-
wi se di recti on approxi matel y 30 degrees.
(3) Pul l the swi tch rearward and remove i t from
i ts mounti ng bracket.
(4) Di sconnect the cl utch cabl e from the cl utch
pedal spacer (Fi g. 41).
(5) Di sconnect the wi ri ng harness connector goi ng
to the cl utch pedal swi tches (Fi g. 42).
(6) Remove the cl i p securi ng the power brake
booster i nput rod to the brake pedal (Fi g. 39).
Remove the i nput rod from the brake pedal .
(7) Remove the four nuts fasteni ng the brake pedal
bracket to the power brake booster (Fi g. 40).
(8) Remove the two nuts fasteni ng the brake pedal
bracket to the i nstrument panel support (Fi g. 40).
(9) Remove the brake pedal assembl y.
(10) The pedal can be removed from i t’s bracket by
gri ndi ng off the peened end of the shaft, removi ng
the shaft, pedal and bushi ngs. A servi ce parts pack-
age i s avai l abl e to repl ace these i tems.
INSTALLATION
(1) I f the pedal has been removed from i t’s
bracket, i nstal l the pedal , bushi ngs and bol t-i n-shaft
on the bracket usi ng the avai l abl e servi ce parts pack-
age.
(2) I nstal l the brake pedal assembl y onto the studs
extendi ng down from the i nstrument panel support
and power brake booster (Fi g. 40).
(3) I nstal l the two nuts fasteni ng the brake pedal
bracket to the i nstrument panel support (Fi g. 40).
I nstal l the nuts al l the way, but do not ti ghten them
at thi s ti me.
Fig. 41 Clutch Cable Connection
1 – SNAP RING
2 – CLUTCH PEDAL SPACER
3 – CLUTCH PEDAL
4 – CLUTCH CABLE
Fig. 42 Wiring Harness Connector
1 – UPSTOP SWITCH
2 – CLUTCH PEDAL
3 – INTERLOCK SWITCH
4 – CONNECTOR
5 - 26 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l the power brake booster mounti ng nuts.
Ti ghten the four nuts fasteni ng the brake pedal
bracket to the power brake booster to a torque of 34
N·m (300 i n. l bs.).
(5) Ti ghten the two nuts fasteni ng the brake pedal
bracket to the i nstrument panel support to a torque
of 34 N·m (300 i n. l bs.).
(6) Connect the cl utch cabl e to the cl utch pedal
spacer on the pedal (Fi g. 41).
(7) Connect the wi ri ng harness connector goi ng to
the cl utch pedal swi tches (Fi g. 42).
(8) I nstal l the power brake booster i nput rod on
the pi n mounted on the si de of the brake pedal .
I nstal l a new retai ni ng cl i p on the end of the pi n
(Fi g. 39). Do not reuse the ol d cl i p.
NOTE: Prior to installing the brake lamp switch,
make sure the plunger is at it’s fully extended posi-
tion.
(9) Hol d the brake l amp swi tch fi rml y i n one hand.
Then usi ng the other hand, pul l outward on the
pl unger of the brake l amp swi tch unti l i t has ratch-
eted out to i ts ful l y extended posi ti on.
(10) Mount the brake l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure:
• Depress the brake pedal as far down as possi bl e.
• I nstal l the swi tch i n i ts bracket by al i gni ng the
i ndex tab on the swi tch wi th the sl ot i n the mounti ng
bracket.
• When the swi tch i s ful l y seated i n i ts bracket,
rotate the swi tch cl ockwi se approxi matel y 30° to l ock
the swi tch i nto pl ace.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(11) Gentl y pul l back on the brake pedal unti l the
pedal stops movi ng. Thi s wi l l ratchet the swi tch
pl unger backward to the correct adjustment posi ti on.
(12) I nstal l the i nstrument panel . Refer to the
I NSTRUMENT PANELS AND SYSTEMS group i n
thi s servi ce manual for the requi red procedure.
(13) Check the stop l amps to veri fy they are oper-
ati ng properl y and not stayi ng on when the pedal i s
i n the rel eased posi ti on.
(14) Road test the vehi cl e to ensure proper opera-
ti on of the brakes.
BRAKE LAMP SWITCH
REMOVAL
(1) Depress and hol d the brake pedal whi l e rotat-
i ng the brake l amp swi tch (Fi g. 43) i n a countercl ock-
wi se di recti on approxi matel y 30 degrees.
(2) Pul l the swi tch rearward and remove i t from
i ts mounti ng bracket.
(3) Di sconnect the wi ri ng harness connector from
the brake l amp swi tch.
INSTALLATION
NOTE: Prior to installing brake lamp switch into
bracket, the plunger must be moved to its fully
extended position using the procedure in Step 1.
(1) Hol d the brake l amp swi tch fi rml y i n one hand.
Then usi ng the other hand, pul l outward on the
pl unger of the swi tch unti l i t has ratcheted out to i ts
ful l y extended posi ti on.
(2) Connect the wi ri ng harness connector to the
brake l amp swi tch.
(3) Mount the brake l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure:
• Depress the brake pedal as far down as possi bl e.
• I nstal l the swi tch i n i ts bracket by al i gni ng the
i ndex tab on the swi tch wi th the sl ot i n the mounti ng
bracket.
• When the swi tch i s ful l y seated i n i ts bracket,
rotate the swi tch cl ockwi se approxi matel y 30° to l ock
the swi tch i nto pl ace (Fi g. 43).
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
Fig. 43 Brake Lamp Switch
1 – SWITCH
2 – CLIP
3 – BRAKE PEDAL
4 – CONNECTOR
PL BRAKES 5 - 27
REMOVAL AND INSTALLATION (Continued)
(4) Gentl y pul l back on the brake pedal unti l the
pedal stops movi ng. Thi s wi l l ratchet the swi tch
pl unger backward to the correct adjustment posi ti on.
(5) Check the stop l amps to veri fy they are operat-
i ng properl y and not stayi ng on when the pedal i s i n
the rel eased posi ti on.
MASTER CYLINDER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) Wi th the engi ne not runni ng, pump the brake
pedal 4-5 strokes unti l the pedal feel i s fi rm.
(2) Di sconnect the negati ve (ground) cabl e from
the battery and i sol ate the cabl e.
(3) Di sconnect the posi ti ve cabl e from the battery,
then remove the battery from the battery tray. There
i s one nut securi ng the cl amp on the backsi de of the
battery hol di ng i t i n pl ace.
(4) Remove the vehi cl e wi ri ng harness connector
from brake fl ui d l evel swi tch i n master cyl i nder
brake fl ui d reservoi r (Fi g. 44).
(5) Di sconnect the two brake tubes from the mas-
ter cyl i nder, and two brake tubes from the propor-
ti oni ng val ves (Fi g. 45). I nstal l pl ugs at al l of the
open brake tube outl ets on the master cyl i nder.
(6) Cl ean the area around where the master cyl i n-
der attaches to the power brake booster usi ng a sui t-
abl e brake cl eaner such as Mopar௡ Brake Parts
Cl eaner or an equi val ent.
(7) Remove the two nuts attachi ng the master cyl -
i nder to the power brake booster.
(8) Sl i de the master cyl i nder strai ght out of the
power brake booster.
(9) To remove the proporti oni ng val ves, unthread
each from the master cyl i nder.
INSTALLATION
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) I f removed, i nstal l the proporti oni ng val ves i n
thei r master cyl i nder ports. The val ves are i denti cal ,
so they can be i nstal l ed i n ei ther master cyl i nder
port goi ng to the rear brakes. Make sure the O-ri ngs
on the proporti oni ng val ves are new.
(2) Bl eed the master cyl i nder before i nstal l i ng i t
on the vehi cl e. Refer to MASTER CYLI NDER
BLEEDI NG i n SERVI CE PROCEDURES wi thi n thi s
secti on of thi s servi ce manual group.
(3) Wi pe the face of the power brake booster cl ean
where the master cyl i nder seal comes i n contact
when i t’s i nstal l ed. Do not get any cl eaner or debri s
i nsi de the booster.
Fig. 44 Master Cylinder
1 – POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG
2 – POWER BRAKE BOOSTER
3 – BRAKE FLUID PRESSURE SWITCH
4 – MASTER CYLINDER
Fig. 45 Brake Tubes At Master Cylinder
1 – RIGHT FRONT BRAKE TUBE
2 – LEFT FRONT BRAKE TUBE
3 – LEFT REAR BRAKE TUBE
4 – REAR PROPORTIONING VALVES
5 – RIGHT REAR BRAKE TUBE
5 - 28 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(4) Posi ti on the master cyl i nder on the studs of the
power brake booster, al i gni ng the push rod of the
power brake booster wi th master cyl i nder pi ston
push rod. Careful l y push the master cyl i nder onto
the studs unti l i t contacts the face of the booster.
(5) I nstal l the two master cyl i nder mounti ng nuts
and ti ghten each to a torque of 28 N·m (250 i n. l bs.).
(6) Connect the four brake tubes to the master cyl -
i nder and proporti oni ng val ve ports (Fi g. 45). Ti ghten
al l tube nuts to a torque of 17 N·m (145 i n. l bs.).
(7) Connect the brake fl ui d l evel swi tch wi ri ng
connector.
(8) I nstal l the battery and cl amp i t i n pl ace.
(9) Connect the posi ti ve, then the negati ve
(ground) cabl e on the battery.
(10) Fi l l the master cyl i nder to the proper l evel .
(11) Road test the vehi cl e to ensure proper opera-
ti on of the brakes.
BRAKE FLUID RESERVOIR
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: The master cylinder does not need to be
removed from the power brake booster for removal
and installation of the brake fluid reservoir.
REMOVAL
(1) Cl ean the master cyl i nder housi ng and brake
fl ui d reservoi r exteri or surfaces.
(2) Remove the brake fl ui d reservoi r cap. Usi ng a
cl ean syri nge or si phoni ng tool , empty as much brake
fl ui d as possi bl e from the reservoi r.
(3) Remove the vehi cl e wi ri ng harness connector
from brake fl ui d l evel swi tch i n master cyl i nder
brake fl ui d reservoi r (Fi g. 44).
(4) Remove the two pl asti c pi ns hol di ng the reser-
voi r to the master cyl i nder (Fi g. 46).
(5) Li ft the reservoi r from the master cyl i nder
casti ng.
(6) Remove the grommets seal i ng the reservoi r to
the master cyl i nder housi ng (Fi g. 47).
INSTALLATION
(1) I nstal l new seal i ng grommets i n the master
cyl i nder housi ng (Fi g. 47).
(2) Lubri cate the seal i ng grommets wi th fresh
cl ean DOT 3 brake fl ui d. Pl ace the reservoi r i n posi -
ti on over the grommets maki ng sure the fi l l er hol e i s
towards the front of the vehi cl e. Seat the reservoi r
i nto the grommets. Whi l e hol di ng the reservoi r fi rml y
agai nst the grommets, i nstal l the two pl asti c pi ns
previ ousl y removed through thei r mounti ng hol es
unti l they protrude out the other si de of the master
cyl i nder reservoi r (Fi g. 46).
(3) Connect the brake fl ui d l evel swi tch wi ri ng
connector (Fi g. 44).
Fig. 46 Master Cylinder Reservoir
1 – BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 – RESERVOIR RETAINING PINS
3 – SEAL
Fig. 47 Sealing Grommets
1 – MASTER CYLINDER
2 – GROMMETS
3 – SEAL
PL BRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)
(4) Fi l l the reservoi r wi th fresh cl ean DOT 3 brake
fl ui d. Refer to BRAKE FLUI D LEVEL CHECKI NG
i n the SERVI CE PROCEDURES secti on i n thi s sec-
ti on of thi s servi ce manual group.
BRAKE FLUID LEVEL SWITCH
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Remove the vehi cl e wi ri ng harness connector
from brake fl ui d l evel swi tch i n master cyl i nder
brake fl ui d reservoi r (Fi g. 44).
(2) Push together the retai ni ng tabs hol di ng the
brake fl ui d l evel swi tch i n pl ace i n the brake fl ui d
reservoi r (Fi g. 46).
(3) Pul l the brake fl ui d l evel swi tch out the other
si de of the reservoi r.
INSTALLATION
(1) Al i gn the brake fl ui d l evel swi tch wi th i ts
mounti ng hol e on the l eft si de of the master cyl i nder
brake fl ui d reservoi r. Push the swi tch i nto the fl ui d
reservoi r unti l the swi tch retai ni ng tabs are
expanded on the other si de of the reservoi r, l ocki ng i t
i n pl ace (Fi g. 46).
(2) Connect the brake fl ui d l evel swi tch wi ri ng
connector (Fi g. 44).
POWER BRAKE BOOSTER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Di sconnect negati ve (ground) cabl e from the
battery and i sol ate the cabl e.
(2) Di sconnect the posi ti ve cabl e from the battery,
then remove the battery from the battery tray. There
i s one nut securi ng the cl amp on the backsi de of the
battery hol di ng i t i n pl ace.
(3) Remove the one nut and one bol t securi ng the
ai r cl eaner box i n pl ace, then di sconnect the wi ri ng
harness connector at the ai r i nl et sensor.
(4) Li ft the ai r cl eaner box upward enough to cl ear
i ts grommeted al i gnment post (Fi g. 48), then move
the ai r cl eaner box forward just enough to access the
battery tray mounti ng bol ts.
(5) Remove the 2 bol ts, then the 2 nuts mounti ng
the battery tray to i ts bracket (Fi g. 48). Remove the
battery tray.
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal 4-5 times while the engine is not run-
ning until a firm brake pedal is achieved.
(6) Remove the master cyl i nder. For the master
cyl i nder wi thout ABS removal and i nstal l ati on proce-
dure, refer to MASTER CYLI NDER i n thi s secti on of
thi s servi ce manual group. For the master cyl i nder
wi th ABS removal and i nstal l ati on procedure, refer
to MASTER CYLI NDER i n the ANTI LOCK BRAKE
SYSTEM secti on of thi s servi ce manual group.
(7) I f the vehi cl e i s equi pped wi th ABS, remove the
i ntegrated control uni t (I CU). Refer to I NTEGRATED
CONTROL UNI T i n REMOVAL AND I NSTALLA-
TI ON wi thi n the ANTI LOCK BRAKE SYSTEM sec-
ti on of thi s servi ce manual group for the procedure.
(8) I f the vehi cl e i s equi pped wi th ABS, remove the
three bol ts securi ng the I CU mounti ng bracket to the
frame rai l .
(9) Di sconnect the vacuum hoses from the check
val ve on the power brake booster (Fi g. 49), but do not
remove the check val ve from power brake booster.
(10) Locate the brake pedal -to-power brake booster
i nput rod attachment under the i nstrument panel .
Posi ti on a smal l screwdri ver (Fi g. 50) under the cen-
ter tang of the retai ni ng cl i p. Rotate the screwdri ver
enough to al l ow the retai ni ng cl i p tang to pass over
the end of the brake pedal pi n. Remove the cl i p.
Fig. 48 Battery Tray Mounting
1 – BATTERY TRAY MOUNTING NUTS
2 – BATTERY TRAY MOUNTING BOLTS
3 – AIR CLEANER BOX POST
5 - 30 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
CAUTION: Discard the used retaining clip, it is not
to be reused. Replace the clip with a new one on
reassembly.
(11) Remove the four nuts attachi ng the power
brake booster to the i nstrument panel (Fi g. 51). The
nuts are accessi bl e from under the i nstrument panel
i n the area of the brake pedal bracket.
(12) Sl i de the power brake booster forward unti l
mounti ng studs cl ear the i nstrument panel . Turn the
booster si deways (Fi g. 52), then remove i t from the
vehi cl e.
INSTALLATION
(1) Turn the power brake booster si deways (Fi g.
52), then i nstal l i t i nto the engi ne compartment down
past the heater hoses and the strut tower. Rotate the
booster so i ts four mounti ng studs and i nput rod are
poi nted strai ght toward the i nstrument panel . Sl i de
the i nput rod and studs through the i nstrument
panel and i nto mounti ng posi ti on.
(2) Under the i nstrument panel , i nstal l the four
power brake booster mounti ng nuts (Fi g. 51). Ti ghten
the nuts to a torque of 34 N·m (300 i n. l bs.).
(3) Usi ng l ubri pl ate, or an equi val ent, coat the sur-
face of the brake pedal pi n where i t contacts the
brake booster i nput rod.
Fig. 49 Vacuum Check Valve
1 – VACUUM CHECK VALVE
Fig. 50 Retaining Clip
1 – BRAKE PEDAL
2 – INPUT ROD
3 – SCREWDRIVER
4 – RETAINING CLIP
5 – BRAKE PEDAL PIN
Fig. 51 Power Brake Booster Mounting
1 – POWER BRAKE BOOSTER MOUNTING NUTS
2 – BRAKE PEDAL
Fig. 52 Booster Removal/Installation
1 – POWER BRAKE BOOSTER
PL BRAKES 5 - 31
REMOVAL AND INSTALLATION (Continued)
CAUTION: Use only a new brake booster input rod-
to-brake pedal retaining clip to ensure proper
retainment.
(4) Connect the power brake booster i nput rod-to-
brake pedal pi n. I nstal l a new retai ni ng cl i p. Do not
use the ol d cl i p.
(5) Connect al l previ ousl y removed vacuum hoses
to the vacuum check val ve (Fi g. 49).
(6) I f the vehi cl e i s equi pped wi th ABS, i nstal l the
I CU mounti ng bracket on the frame rai l usi ng i ts
three bol ts. Ti ghten the nuts to a torque of 23 N·m
(200 i n. l bs.).
(7) I f the vehi cl e i s equi pped wi th ABS, rei nstal l
the I CU. Refer to I NTEGRATED CONTROL UNI T i n
REMOVAL AND I NSTALLATI ON wi thi n the
ANTI LOCK BRAKE SYSTEM secti on of thi s servi ce
manual group for the procedure.
(8) I nstal l the master cyl i nder. For the master cyl -
i nder wi thout ABS removal and i nstal l ati on proce-
dure, refer to MASTER CYLI NDER i n thi s secti on of
thi s servi ce manual group. For the master cyl i nder
wi th ABS removal and i nstal l ati on procedure, refer
to MASTER CYLI NDER i n the ANTI LOCK BRAKE
SYSTEM secti on of thi s servi ce manual group.
(9) Posi ti on the battery tray back i n pl ace. I nstal l
the two bol ts, then the two nuts mounti ng the bat-
tery tray to i ts bracket (Fi g. 48). Ti ghten the two
bol ts and nuts to a torque of 34 N·m (25 ft. l bs.).
(10) Rei nstal l the ai r cl eaner box onto i ts grom-
meted al i gnment post (Fi g. 48).
(11) I nstal l the one nut and one bol t securi ng the
ai r cl eaner box i n pl ace, then connect the wi ri ng har-
ness connector at the ai r i nl et sensor.
(12) I nstal l the battery and cl amp i t i n pl ace.
(13) Connect the posi ti ve, then the negati ve
(ground) cabl e on the battery.
(14) Adjust the stop l amp swi tch as necessary.
Refer to STOP LAMP SWI TCH i n the ADJUST-
MENTS secti on of thi s group.
(15) Bl eed the base brake system.
(16) Road test the vehi cl e to ensure proper opera-
ti on of the brakes.
PROPORTIONING VALVE
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Usi ng a brake pedal hol der, depress the brake
pedal past i ts fi rst one i nch of travel and hol d i t i n
thi s posi ti on (Fi g. 53). Thi s wi l l i sol ate the master
cyl i nder from the brake hydraul i c system and wi l l
not al l ow the brake fl ui d to drai n out of the master
cyl i nder reservoi r.
(2) Di sconnect the brake tube from the proporti on-
i ng val ve requi ri ng removal (Fi g. 54).
(3) Unscrew the Proporti oni ng val ve from the mas-
ter cyl i nder.
Fig. 53 Brake Pedal Holder
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 54 Proportioning Valves On Master Cylinder
1 – RIGHT FRONT BRAKE TUBE
2 – LEFT FRONT BRAKE TUBE
3 – LEFT REAR BRAKE TUBE
4 – REAR PROPORTIONING VALVES
5 – RIGHT REAR BRAKE TUBE
5 - 32 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Lubri cate the O-ri ng on the proporti oni ng
val ve. Make sure the O-ri ng on the proporti oni ng
val ve i s new.
(2) I nstal l the proporti oni ng val ve i n i ts master
cyl i nder port. Ti ghten the proporti oni ng val ve to a
torque of 40 N·m (30 ft. l bs.).
(3) Connect the brake tube to the proporti oni ng
val ve (Fi g. 54). Ti ghten the tube nut to a torque of 17
N·m (145 i n. l bs.).
(4) Remove the brake pedal hol der (Fi g. 53).
(5) Bl eed the affected brake l i ne. See BASE
BRAKE BLEEDI NG i n the SERVI CE PROCE-
DURES secti on i n thi s servi ce manual group.
(6) Road test the vehi cl e to ensure proper opera-
ti on of the brakes.
BRAKES TUBES AND HOSES
NOTE: Brake hoses for each brake are unique and
are not interchangeable.
Al ways use Mopar௡ repl acement brake hoses to
ensure qual i ty, correct l ength and superi or fati gue
l i fe. Care shoul d be taken to make sure that the tube
and hose mati ng surfaces are cl ean and free from
ni cks and burrs.
Use new copper seal washers on al l connecti ons
usi ng banjo bol ts and ti ghten al l the fi tti ngs to thei r
speci fi ed torques.
Fol l ow the procedures i n the next three paragraphs
to reduce the potenti al for twi sti ng the brake hose
duri ng i nstal l ati on.
The fl exi bl e front hydraul i c brake hose shoul d
al ways be i nstal l ed on the vehi cl e by fi rst attachi ng
the banjo fi tti ng to the di sc brake cal i per. Attach the
hose to the brake tubi ng before attachi ng i t to the
front frame rai l . Ti ghten al l brake l i ne fi tti ngs to the
speci fi ed torque.
On vehi cl es equi pped wi th rear drum brakes,
l oosel y i nstal l the rear brake hose to the wheel cyl i n-
der fi rst, then bol t the i ntermedi ate routi ng bracket
to the strut. Next, l oosel y i nstal l the hose to the steel
tube comi ng from the master cyl i nder. Attach the
hose bracket to the body. Fi nal l y, ti ghten the tube
nuts at each end of the brake hose.
On vehi cl es equi pped wi th rear di sc brakes, attach
the brake hose banjo fi tti ng to the cal i per fi rst, then
l oosel y i nstal l the hose to the steel tube comi ng from
the master cyl i nder. Next, attach the brake hose
bracket to the body. Fi nal l y, ti ghten the tube nut at
the each of the end of the brake hose connecti ng to
the steel tube comi ng from the master cyl i nder.
Onl y doubl e wal l 4.75 mm (3/16 i n.) steel brake
l i ne tubi ng wi th Nygal coati ng shoul d be used for
repl acement al ong wi th i ts speci al tube nuts. Care
must be taken when repl aci ng brake tubi ng; to be
sure, use the proper bendi ng and fl ari ng tool s, and
procedures to avoi d ki nki ng. Do not route the tubes
agai nst sharp edges, movi ng components, or i nto hot
areas. Al l tubes shoul d be properl y attached wi th the
recommended retai ni ng cl i ps.
DISC BRAKE CALIPER (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Usi ng a brake pedal hol di ng tool as shown (Fi g.
55), depress the brake pedal past i ts fi rst one i nch of
travel and hol d i t i n thi s posi ti on. Thi s wi l l i sol ate
the master cyl i nder from the brake hydraul i c system
and wi l l not al l ow the brake fl ui d to drai n out of the
master cyl i nder reservoi r when the l i nes are opened.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(3) Remove the front ti re and wheel assembl y.
Fig. 55 Brake Pedal Holding Tool
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
PL BRAKES 5 - 33
REMOVAL AND INSTALLATION (Continued)
(4) Remove the banjo bol t connecti ng the brake
hose to the brake cal i per (Fi g. 56). There are two
washers (one on each si de of the fl ex hose fi tti ng)
that wi l l come off wi th the banjo bol t. I nspect and
di scard these i f they are worn or damaged.
(5) Remove the two brake cal i per to steeri ng
knuckl e gui de pi n bol ts (Fi g. 57).
(6) Remove the di sc brake cal i per from the steer-
i ng knuckl e. The cal i per i s removed by fi rst ti ppi ng
ei ther the top (ri ght si de cal i per) or bottom (l eft si de
cal i per) of the cal i per away from the brake rotor,
then pul l i ng the cal i per off the opposi te end’s cal i per
sl i de abutment (on the knuckl e) and brake rotor.
INSTALLATION
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Compl etel y retract the cal i per pi ston back i nto
the bore of the cal i per.
(2) Lubri cate both steeri ng knuckl e cal i per sl i de
abutments wi th a l i beral amount of Mopar௡ Mul ti -
purpose Lubri cant, or an equi val ent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(3) I nstal l the di sc brake cal i per (wi th pads) on the
brake rotor and steeri ng knuckl e. The l eft si de cal i -
per i s i nstal l ed by fi rst sl i di ng the top of the cal i per
past the top cal i per sl i de abutment on the steeri ng
knuckl e to hook the top edge of the cal i per, then
pushi ng the l ower end of the cal i per i nto pl ace
agai nst the knuckl e (Fi g. 58). The ri ght si de cal i per
i s i nstal l ed by fi rst sl i di ng the bottom edge of the cal -
i per past the l ower cal i per sl i de abutment on the
steeri ng knuckl e to hook the l ower edge of the cal i -
per, then pushi ng the top of the cal i per i nto pl ace
agai nst the steeri ng knuckl e.
Fig. 56 Brake Hose Connection
1 – CALIPER
2 – HOSE
3 – BOLT
Fig. 57 Caliper Mounting
1 – RETAINER CLIP
2 – BRAKE ROTOR
3 – HUB
4 – GUIDE PIN BOLTS
5 – DISC BRAKE CALIPER
Fig. 58 Installing Left Caliper
1 – SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 – BRAKING DISC
3 – DISC BRAKE CALIPER
4 – STEERING KNUCKLE BRAKE ABUTMENT
5 - 34 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l the cal i per gui de pi n bol ts and ti ghten
them to a torque of 22 N·m (192 i n. l bs.) (Fi g. 57).
(5) I nstal l the banjo bol t connecti ng the brake hose
to the brake cal i per (Fi g. 56). Pl ace one fi tti ng
washer on each si de of the hose fi tti ng as the banjo
bol t i s gui ded through the fi tti ng. I nstal l new wash-
ers i f they are worn or damaged at al l . Thread the
banjo bol t i nto the cal i per and ti ghten i t to a torque
of 48 N·m (35 ft. l bs.).
(6) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(7) Lower the vehi cl e.
(8) Remove the brake pedal hol di ng tool .
(9) Bl eed the cal i per as necessary. Refer to BASE
BRAKE BLEEDI NG i n the SERVI CE PROCE-
DURES secti on i n thi s servi ce manual group.
(10) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
seat the brake pads.
DISC BRAKE SHOES (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
NOTE: Vehicles that are equipped with optional
Four-wheel-disc brake system use a different lining
material on the front disc brake shoes than vehicles
with front disc and rear drum brakes. When new
brake shoes are installed, be sure the brake shoes
for the correct type of brake system are used.
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove both front ti re and wheel assembl i es
from vehi cl e.
(3) Begi n on one si de of the vehi cl e.
(4) Remove the two brake cal i per gui de pi n bol ts
(Fi g. 59).
(5) Remove the di sc brake cal i per from the steer-
i ng knuckl e. The cal i per i s removed by fi rst ti ppi ng
ei ther the top (ri ght si de cal i per) or bottom (l eft si de
cal i per) of the cal i per away from the brake rotor,
then pul l i ng the cal i per off the opposi te end’s cal i per
sl i de abutment (on the knuckl e) and brake rotor.
(6) Support the cal i per usi ng a wi re or cord to pre-
vent the wei ght of cal i per from damagi ng the brake
hose (Fi g. 60). Do not l et the cal i per hang by the
brake hose.
Fig. 59 Caliper And Rotor Mounting
1 – RETAINER CLIP
2 – BRAKE ROTOR
3 – HUB
4 – GUIDE PIN BOLTS
5 – DISC BRAKE CALIPER
Fig. 60 Supporting Caliper
1 – WIRE HANGER
2 – STEERING KNUCKLE
3 – BRAKE DISC
4 – DISC BRAKE CALIPER ASSEMBLY
5 – BRAKE HYDRAULIC HOSE
PL BRAKES 5 - 35
REMOVAL AND INSTALLATION (Continued)
(7) Remove the outboard brake shoe from the cal i -
per by pryi ng the shoe retai ni ng cl i p over the rai sed
area on the cal i per. Sl i de the brake shoe down and
off of the cal i per (Fi g. 61).
(8) Pul l the i nboard brake shoe away from the cal -
i per pi ston unti l the retai ni ng cl i p i s out of the cavi ty
i n the pi ston (Fi g. 62) and remove the shoe.
(9) Repeat the above procedure to the front brakes
on the other si de of the vehi cl e.
INSTALLATION
(1) Begi n on one si de of the vehi cl e.
(2) Compl etel y retract the cal i per pi ston back i nto
the bore of the cal i per. Thi s i s requi red to gai n the
necessary shoe-to-rotor cl earance for the cal i per
i nstal l ati on onto the steeri ng knuckl e.
(3) Remove any protecti ve paper from the noi se
suppressi on gasket on both the i nner and outer brake
shoes (i f equi pped).
(4) I nstal l the i nboard brake shoe i nto the cal i per
pi ston by fi rml y pressi ng the shoe i n wi th the
thumbs (Fi g. 63). Be sure the i nboard brake shoe i s
posi ti oned squarel y agai nst the face of the cal i per
pi ston.
(5) Sl i de the new outboard brake shoe onto the cal -
i per (Fi g. 64).
(6) Lubri cate both steeri ng knuckl e cal i per sl i de
abutments wi th a l i beral amount of Mopar௡ Mul ti -
purpose Lubri cant, or an equi val ent.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
Fig. 61 Removing Outboard Brake Shoe
1 – CALIPER ASSEMBLY
2 – HANGER WIRE
3 – BRAKE FLEX HOSE
4 – OUTBOARD BRAKE PAD
5 – HUB/BEARING ASSEMBLY
6 – STEERING KNUCKLE
7 – SCREWDRIVER
Fig. 62 Removing Inboard Brake Shoe
1 – INBOARD BRAKE SHOE
2 – HANGER WIRE
3 – CALIPER ASSEMBLY
4 – RETAINING CLIP
5 – PISTON
Fig. 63 Installing Inboard Brake Shoe
1 – PISTON
2 – BRAKE SHOE
3 – CALIPER ASSEMBLY
5 - 36 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(7) I nstal l the di sc brake cal i per (wi th pads) on the
brake rotor and steeri ng knuckl e. The l eft si de cal i -
per i s i nstal l ed by fi rst sl i di ng the top of the cal i per
past the top cal i per sl i de abutment on the steeri ng
knuckl e to hook the top edge of the cal i per, then
pushi ng the l ower end of the cal i per i nto pl ace
agai nst the knuckl e (Fi g. 65). The ri ght si de cal i per
i s i nstal l ed by fi rst sl i di ng the bottom edge of the cal -
i per past the l ower cal i per sl i de abutment on the
steeri ng knuckl e to hook the l ower edge of the cal i -
per, then pushi ng the top of the cal i per i nto pl ace
agai nst the steeri ng knuckl e.
(8) I nstal l the cal i per gui de pi n bol ts and ti ghten
them to a torque of 22 N·m (192 i n. l bs.) (Fi g. 59).
(9) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(10) Repeat the above procedure to the front
brakes on the other si de of the vehi cl e.
(11) Lower the vehi cl e.
(12) Pump the brake pedal before movi ng the vehi -
cl e to set the brake shoes to the brake rotor.
(13) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
seat the brake pads.
BRAKE ROTOR (FRONT)
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the front ti re and wheel assembl y.
(3) Remove the front di sc brake cal i per assembl y
from the brake rotor and store i t out of the way.
Refer to DI SC BRAKE SHOES (FRONT) i n thi s
REMOVAL AND I NSTALLATI ON secti on of thi s ser-
vi ce manual group.
(4) Remove the cl i ps retai ni ng the brake rotor (Fi g.
59).
(5) Remove the brake rotor by pul l i ng i t strai ght
off the wheel mounti ng studs.
INSTALLATION
(1) I nstal l the brake rotor over the wheel mount-
i ng studs and onto the hub (Fi g. 59).
(2) I nstal l the front di sc brake cal i per. I t may be
necessary to retract the brake cal i per pi ston back
i nto the cal i per to fi t the shoes onto the rotor, i f a
new rotor i s bei ng i nstal l ed. Refer to DI SC BRAKE
SHOES (FRONT) i n thi s REMOVAL AND I NSTAL-
LATI ON secti on of thi s servi ce manual group.
(3) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(4) Lower the vehi cl e.
(5) Pump the brake pedal before movi ng the vehi -
cl e to set the brake shoes to the brake rotor.
Fig. 64 Installing Outboard Brake Shoe
1 – BRAKE SHOE ASSEMBLY
2 – BRAKE CALIPER
Fig. 65 Installing Left Caliper
1 – SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT
OF STEERING KNUCKLE AS SHOWN
2 – BRAKING DISC
3 – DISC BRAKE CALIPER
4 – STEERING KNUCKLE BRAKE ABUTMENT
PL BRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)
DISC BRAKE CALIPER (REAR)
REMOVAL
(1) Usi ng a brake pedal hol di ng tool as shown (Fi g.
66), depress the brake pedal past i ts fi rst one i nch of
travel and hol d i t i n thi s posi ti on. Thi s wi l l i sol ate
the master cyl i nder from the brake hydraul i c system
and wi l l not al l ow the brake fl ui d to drai n out of the
master cyl i nder reservoi r whi l e the l i nes are di scon-
nected.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(3) Remove the rear ti re and wheel assembl y.
(4) Remove the banjo bol t connecti ng the brake
hose to the brake cal i per (Fi g. 67). There are two
washers (one on each si de of the fl ex hose fi tti ng)
that wi l l come off wi th the banjo bol t. I nspect and
di scard these i f they are worn or damaged.
(5) Remove the two cal i per gui de pi n bol ts (Fi g.
68).
(6) Remove the cal i per assembl y from the brake
adapter by fi rst rotati ng the top of the cal i per away
from the rotor, and then l i fti ng the cal i per assembl y
off the machi ned abutment on the adapter (Fi g. 69).
INSTALLATION
NOTE: Step (1) below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
Fig. 66 Brake Pedal Holding Tool
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 67 Brake Hose Mounting
1 – BRAKE HOSE
2 – GUIDE PIN BOLTS
3 – CALIPER
4 – BOLT
Fig. 68 Caliper Mounting
1 – DISC BRAKE CALIPER
2 – DISC BRAKE ADAPTER
3 – GUIDE PIN BOLTS
4 – HUB AND BEARING
5 – BRAKE ROTOR
6 – RETAINER CLIP
7 – DUST CAP
8 – NUT
5 - 38 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(1) Compl etel y retract the cal i per pi ston back i nto
pi ston bore of the cal i per.
(2) Lubri cate both adapter cal i per sl i de abutments
wi th a l i beral amount of Mopar௡ Mul ti purpose Lubri -
cant, or an equi val ent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(3) Starti ng wi th the l ower end, careful l y l ower the
cal i per and brake shoes over the brake rotor and
catch the cal i per’s bottom edge behi nd the cal i per
sl i de abutment (Fi g. 69). Rotate the top of the cal i per
i nto mounti ng posi ti on on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(4) Careful l y i nstal l the cal i per gui de pi n bol ts
(Fi g. 68), then ti ghten them to a torque of 22 N·m
(192 i n. l bs.).
(5) I nstal l the banjo bol t connecti ng the brake hose
to the brake cal i per (Fi g. 67). Pl ace one fi tti ng
washer on each si de of the hose fi tti ng as the banjo
bol t i s gui ded through the fi tti ng. I nstal l new wash-
ers i f they are worn or damaged at al l . Thread the
banjo bol t i nto the cal i per and ti ghten i t to a torque
of 48 N·m (35 ft. l bs.).
(6) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(7) Lower the vehi cl e.
(8) Remove the brake pedal hol di ng tool .
(9) Bl eed the cal i per as necessary. Refer to BASE
BRAKE BLEEDI NG i n the SERVI CE PROCE-
DURES secti on i n thi s servi ce manual group.
(10) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
seat the brake shoes.
DISC BRAKE SHOES (REAR)
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove both rear ti re and wheel assembl i es
from vehi cl e.
(3) Begi n on one si de of the vehi cl e.
(4) Remove the two cal i per gui de pi n bol ts (Fi g.
70).
Fig. 69 Removing Caliper From Adapter
1 – BRAKING DISC
2 – CALIPER ADAPTER
3 – CALIPER
4 – LOWER MACHINED ADAPTER ABUTMENT
Fig. 70 Caliper And Rotor Mounting
1 – DISC BRAKE CALIPER
2 – DISC BRAKE ADAPTER
3 – GUIDE PIN BOLTS
4 – HUB AND BEARING
5 – BRAKE ROTOR
6 – RETAINER CLIP
7 – DUST CAP
8 – NUT
PL BRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)
(5) Remove the cal i per assembl y from the brake
adapter by fi rst rotati ng the top of the cal i per away
from the rotor, and then l i fti ng the cal i per assembl y
off the machi ned abutment on the adapter (Fi g. 71).
(6) Hang the brake cal i per from rear strut usi ng
wi re or cord to prevent the wei ght of the cal i per from
damagi ng the brake hose (Fi g. 72).
(7) Remove the outboard brake shoe from the cal i -
per by pryi ng the brake shoe retai ni ng cl i p over the
rai sed area on the cal i per. Then sl i de the brake shoe
down and off of the brake cal i per (Fi g. 73).
(8) Pul l the i nboard brake shoe away from cal i per
pi ston unti l the retai ni ng cl i p i s free from the cavi ty
i n the pi ston (Fi g. 74).
(9) Repeat the above procedure to the rear brakes
on the other si de of the vehi cl e.
INSTALLATION
(1) Begi n on one si de of the vehi cl e.
(2) Compl etel y retract the cal i per pi ston back i nto
pi ston bore of the cal i per. Thi s i s requi red to gai n the
necessary shoe-to-rotor cl earance for the cal i per
i nstal l ati on onto the steeri ng knuckl e.
(3) Remove any protecti ve paper from the noi se
suppressi on gasket on both i nner and outer brake
shoe assembl i es (i f equi pped).
(4) I nstal l the i nboard brake shoe i nto the cal i per
pi ston by fi rml y pressi ng the shoe i n wi th the
thumbs (Fi g. 74). Be sure the i nboard brake shoe i s
posi ti oned squarel y agai nst the face of the cal i per
pi ston.
(5) Sl i de the outboard brake shoe onto the cal i per
assembl y (Fi g. 73). Be sure the retai ni ng cl i p i s
squarel y seated i n the depressed areas on the cal i per.
Fig. 71 Caliper Removal/Installation
1 – BRAKING DISC
2 – CALIPER ADAPTER
3 – CALIPER
4 – LOWER MACHINED ADAPTER ABUTMENT
Fig. 72 Supporting Caliper
1 – FLEX HOSE
2 – STRUT
3 – WIRE HANGER
4 – CALIPER ASSEMBLY
Fig. 73 Outboard Brake Shoe
1 – CALIPER FINGERS
2 – RETAINING CLIP
5 - 40 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(6) Lubri cate both adapter cal i per sl i de abutments
wi th a l i beral amount of Mopar௡ Mul ti purpose Lubri -
cant, or an equi val ent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(7) Starti ng wi th the l ower end, careful l y l ower the
cal i per and brake shoes over the brake rotor and
catch the cal i per’s bottom edge behi nd the cal i per
sl i de abutment (Fi g. 71). Rotate the top of the cal i per
i nto mounti ng posi ti on on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(8) Careful l y i nstal l the cal i per gui de pi n bol ts
(Fi g. 70), then ti ghten them to a torque of 22 N·m
(192 i n. l bs.).
(9) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(10) Repeat the above procedure to the rear brakes
on the other si de of the vehi cl e.
(11) Lower the vehi cl e.
(12) Pump the brake pedal several ti mes to ensure
the vehi cl e has a fi rm brake pedal before movi ng the
vehi cl e.
(13) Road test the vehi cl e and make several stops
to wear off any forei gn materi al on the brakes and to
seat the brake shoes.
BRAKE ROTOR (REAR)
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the rear ti re and wheel assembl y.
(3) Remove the rear di sc brake cal i per assembl y
from the brake rotor and store i t out of the way.
Refer to DI SC BRAKE SHOES (REAR) i n thi s
REMOVAL AND I NSTALLATI ON secti on of thi s ser-
vi ce manual group.
(4) Remove any cl i ps retai ni ng the brake rotor
(Fi g. 70).
(5) Remove the brake rotor by pul l i ng i t strai ght
off the wheel mounti ng studs.
INSTALLATION
NOTE: Inspect the disc brake shoes and parking
brake shoes before brake rotor installation.
(1) I nstal l the rear brake rotor over the wheel
mounti ng studs and onto the hub (Fi g. 70).
(2) I nstal l rear di sc brake cal i per. Refer to DI SC
BRAKE SHOES (REAR) i n thi s REMOVAL AND
I NSTALLATI ON secti on of thi s servi ce manual
group.
(3) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(4) Adjust the parki ng brake shoes as necessary.
Refer to ADJUSTMENTS i n thi s secti on of thi s ser-
vi ce manual group.
(5) Lower the vehi cl e.
(6) Pump the brake pedal before movi ng the vehi -
cl e to set the brake shoes to the brake rotor.
DRUM BRAKE WHEEL CYLINDER (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
Fig. 74 Inboard Brake Shoe
1 – RETAINING CLIP
2 – INBOARD SHOE
PL BRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Usi ng a brake pedal hol der, depress the brake
pedal past i ts fi rst one i nch of travel and hol d i t i n
thi s posi ti on (Fi g. 75). Thi s wi l l i sol ate the master
cyl i nder from the brake hydraul i c system and wi l l
not al l ow the brake fl ui d to drai n out of the master
cyl i nder reservoi r.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(3) Remove the rear ti re and wheel assembl y.
(4) Di sconnect the rear brake fl ex hose from the
wheel cyl i nder (Fi g. 76).
(5) Remove the rear brake drum.
(6) Remove the rear brake shoes from the brake
support pl ate. Refer to DRUM BRAKE SHOES i n
thi s REMOVAL AND I NSTALLATI ON secti on.
NOTE: If the brake shoes are wet with grease or
brake fluid, replace them.
(7) Remove the brake wheel cyl i nder attachi ng
bol ts (Fi g. 76).
(8) Remove the brake wheel cyl i nder from the
brake support pl ate (Fi g. 77).
INSTALLATION
(1) I nstal l a new O-ri ng at the mati ng surface of
the wheel cyl i nder-to-brake support pl ate (Fi g. 77).
NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake assembly.
(2) I nstal l the wheel cyl i nder onto brake support
pl ate (Fi g. 77). Ti ghten the attachi ng bol ts to a
torque of 13 N·m (115 i n. l bs.).
(3) Hand start the rear brake fl ex hose tube fi tti ng
to wheel cyl i nder. Ti ghten the tube nut to a torque of
17 N·m (145 i n. l bs.).
(4) I nstal l the rear brake shoes on the brake sup-
port pl ate. Repl ace them as necessary.
(5) I nstal l the rear brake drum onto the rear hub.
Fig. 75 Brake Pedal Holder
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 76 Brake Flex Hose At Wheel Cylinder
1 – BRAKE SUPPORT PLATE
2 – WHEEL CYLINDER ATTACHING BOLTS
3 – REAR BRAKE FLEX HOSE TUBE
4 – WHEEL CYLINDER ASSEMBLY
Fig. 77 Remove/Install Wheel Cylinder
1 – WHEEL CYLINDER
2 – SUPPORT PLATE
3 – O-RING
5 - 42 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(6) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(7) Adjust the rear brakes. Refer to ADJUST-
MENTS i n thi s secti on of thi s servi ce manual group.
(8) Lower the vehi cl e.
(9) Remove the brake pedal hol der.
(10) Bl eed the wheel cyl i nder as necessary. Refer
to BASE BRAKE BLEEDI NG i n the SERVI CE PRO-
CEDURES secti on i n thi s servi ce manual group.
(11) Road test the vehi cl e to make sure the brakes
operate correctl y.
DRUM BRAKE SHOES (REAR)
NOTE: Before proceeding with this removal and
installation procedure, review the SERVICE WARN-
INGS AND CAUTIONS at the beginning of REMOVAL
AND INSTALLATION in this section.
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove both rear ti re and wheel assembl i es
from the vehi cl e.
(3) Begi n on one si de of the vehi cl e.
(4) Remove the brake drum retai ni ng cl i ps (i f
equi pped) (Fi g. 78).
(5) Remove the brake drum (Fi g. 78).
(6) Remove the automati c adjustment l ever-to-
brake shoe spri ng (Fi g. 79).
(7) Remove the automati c adjustment l ever (Fi g.
80) from the brake shoe.
(8) Remove the hol d down cl i ps and pi ns attachi ng
the l eadi ng and trai l i ng brake shoes to the brake
support pl ate (Fi g. 81).
(9) Remove the l ower brake shoe-to-anchor pl ate
return spri ng (Fi g. 82).
(10) Remove the parki ng brake l ever pi n-to-brake
shoe retai ni ng cl i p (Fi g. 83).
Fig. 78 Drum Brakes
1 – DUST CAP
2 – NUT
3 – DRUM
4 – HUB AND BEARING
5 – WHEEL CYLINDER
6 – SEAL
7 – SUPPORT PLATE
8 – BRAKE SHOES
9 – RETAINER CLIP
Fig. 79 Automatic Adjustment Lever Spring
1 – ADJUSTMENT LEVER
2 – ADJUSTMENT LEVER TO BRAKE SHOE SPRING
3 – HUB/BEARING
4 – LEADING BRAKE SHOE
5 – AUTOMATIC ADJUSTER SCREW
Fig. 80 Automatic Adjustment Lever
1 – AUTOMATIC ADJUSTMENT LEVER
2 – FRONT BRAKE SHOE ASSEMBLY
PL BRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)
(11) Remove the l eadi ng and trai l i ng brake shoes,
upper return spri ng and automati c adjuster screw
from the brake support pl ate as an assembl y (Fi g.
84).
(12) Di sassembl e the shoes compl etel y once on the
bench.
(13) Repeat the above procedure to the rear brakes
on the other si de of the vehi cl e.
INSTALLATION
(1) Begi n on one si de of the vehi cl e.
(2) Lubri cate the ei ght shoe contact areas on the
support pl ate and anchor usi ng Mopar௡ Mul ti -Pur-
pose Lubri cant or equi val ent (Fi g. 85).
(3) Assembl e the front and rear brake shoe assem-
bl y, automati c adjuster screw, and upper return
spri ng before i nstal l ati on on the vehi cl e.
(4) I nstal l the pre-assembl ed brake shoes, auto-
mati c adjuster screw and upper return spri ng on the
brake support pl ate (Fi g. 84).
(5) I nstal l the wave washer on the pi n of park
brake l ever.
Fig. 81 Brake Shoe Hold Down Clips And Pins
1 – HOLD DOWN CLIP
2 – BRAKE SHOE
3 – SUPPORT PLATE
4 – PIN
Fig. 82 Brake Shoe To Anchor Plate Return Spring
1 – ANCHOR PLATE
2 – LOWER BRAKE SHOE RETURN SPRING
3 – REAR BRAKE SHOE
4 – FRONT BRAKE SHOE
5 – BRAKE SUPPORT PLATE
Fig. 83 Parking Brake Lever Pin To Brake Shoe
Retaining Clip
1 – RETAINING CLIP
2 – PARK BRAKE LEVER PIN
3 – PARK BRAKE LEVER
Fig. 84 Brake Shoe Removal/Installation
1 – UPPER RETURN SPRING
2 – AUTOMATIC ADJUSTER SCREW
3 – TRAILING BRAKE SHOE
4 – WHEEL MOUNTING STUDS
5 – LEADING BRAKE SHOE
6 – BRAKE SUPPORT PLATE
5 - 44 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(6) I nstal l the pi n on the parki ng brake l ever i nto
hol e i n rear brake shoe assembl y (Fi g. 86).
(7) I nstal l both brake shoe-to-brake support pl ate
hol d down pi ns and cl i ps (Fi g. 81).
(8) I nstal l the l ower brake shoe-to-anchor pl ate
return spri ng (Fi g. 82).
(9) I nstal l the automati c adjustment l ever on the
l eadi ng brake shoe (Fi g. 80).
(10) I nstal l the automati c adjustment l ever-to-
brake shoe spri ng (Fi g. 79).
(11) Adjust the brake shoes out unti l the drum
l i ghtl y drags on the shoes when i t i s i nstal l ed. Do not
over-adjust the brakes.
(12) I nstal l the brake drum (Fi g. 78).
(13) Repeat the above procedure to the rear brakes
on the other si de of the vehi cl e.
(14) I nstal l the ti re and wheel assembl i es. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(15) Adjust the rear brake shoes. Refer to
ADJUSTMENTS i n thi s secti on of thi s servi ce man-
ual group.
(16) Lower the vehi cl e.
(17) Road test vehi cl e stoppi ng i n both the forward
and reverse di recti ons. The automati c adjuster wi l l
conti nue to adjust the brakes duri ng the road test of
the vehi cl e.
BRAKE DRUM (REAR)
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the rear ti re and wheel assembl y from
the vehi cl e.
(3) Remove the brake drum retai ni ng cl i ps (i f
equi pped) (Fi g. 87).
Fig. 85 Shoe Contact Areas on Support Plate
Fig. 86 Parking Brake Lever Pin Retaining Clip
Installation
1 – BRAKE SHOE ASSEMBLY
2 – RETAINING CLIP
3 – SCREWDRIVER
4 – PARK BRAKE LEVER
5 – PARK BRAKE LEVER PIN
Fig. 87 Drum Brakes
1 – DUST CAP
2 – NUT
3 – DRUM
4 – HUB AND BEARING
5 – WHEEL CYLINDER
6 – SEAL
7 – SUPPORT PLATE
8 – BRAKE SHOES
9 – RETAINER CLIP
PL BRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)
(4) Remove the brake drum (Fi g. 87).
NOTE: If the drum does not come off, further brake
clearance can be obtained by backing off the brake
automatic adjuster screw. Remove the rubber plug
from the top of brake support plate. Rotate the
automatic adjuster screw in an upward motion,
using a screwdriver.
INSTALLATION
NOTE: Before installing the drum, inspect the brake
shoe linings for wear, shoe alignment, and contam-
ination.
(1) I nstal l the rear brake drum on rear hub and
beari ng (Fi g. 87).
(2) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(3) Adjust the rear brake shoes as necessary. Refer
to ADJUSTMENTS i n thi s secti on of thi s servi ce
manual group.
(4) Lower the vehi cl e.
DRUM BRAKE SHOE SUPPORT PLATE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Usi ng a brake pedal hol di ng tool as shown (Fi g.
88), depress the brake pedal past i ts fi rst one i nch of
travel and hol d i t i n thi s posi ti on. Thi s wi l l i sol ate
the master cyl i nder from the brake hydraul i c system
and wi l l not al l ow the brake fl ui d to drai n out of the
master cyl i nder reservoi r.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(3) Remove the rear ti re and wheel assembl y from
the vehi cl e.
(4) Di sconnect the rear brake fl ex hose from the
wheel cyl i nder (Fi g. 89).
(5) Remove the rear brake drum.
(6) Remove the dust cap (Fi g. 90) from the rear
hub and beari ng.
(7) Remove the nut (Fi g. 91) hol di ng the rear hub
and beari ng to the spi ndl e. Remove the hub and
beari ng from the spi ndl e.
(8) Remove the rear brake shoes from the brake
support pl ate. Refer to DRUM BRAKE SHOES i n
thi s REMOVAL AND I NSTALLATI ON secti on.
(9) Remove the parki ng brake actuator l ever from
the parki ng brake cabl e.
(10) Posi ti on a 1/2 i nch wrench over the retai ner
fi ngers on the end of the parki ng brake cabl e (Fi g.
92). Compress the cabl e housi ng retai ni ng fi ngers
wi th the wrench, then pul l the cabl e housi ng out of
the support pl ate. Remove the wrench as the parki ng
brake cabl e retai ner i s freed from the mounti ng hol e
i n the brake support pl ate.
Fig. 88 Brake Pedal Holding Tool
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 89 Brake Flex Hose At Wheel Cylinder
1 – BRAKE SUPPORT PLATE
2 – WHEEL CYLINDER ATTACHING BOLTS
3 – REAR BRAKE FLEX HOSE TUBE
4 – WHEEL CYLINDER ASSEMBLY
5 - 46 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(11) Remove the 4 brake support pl ate mounti ng
bol ts and washers. Separate brake support pl ate
from rear suspensi on knuckl e.
(12) Remove the brake wheel cyl i nder attachi ng
bol ts.
(13) Remove the brake wheel cyl i nder from the
brake support pl ate.
INSTALLATION
(1) I nstal l a new O-ri ng at the mati ng surface of
the wheel cyl i nder-to-brake support pl ate.
NOTE: When installing wheel cylinder on brake
support plate, be sure it is positioned squarely (hor-
izontal) to the brake support plate.
(2) I nstal l the wheel cyl i nder onto brake support
pl ate. Ti ghten the attachi ng bol ts to a torque of 13
N·m (115 i n. l bs.).
(3) I nstal l the brake support pl ate and gasket on
rear suspensi on knuckl e. Ti ghten the support pl ate
mounti ng bol ts to a torque of 75 N·m (55 ft. l bs.).
(4) I nsert the parki ng brake cabl e i nto i ts mount-
i ng hol e i n the brake support pl ate. Push the cabl e
housi ng i n unti l the retai ner’s fi ngers l ock i nto pl ace.
(5) Hand start the brake fl ex hose tube fi tti ng to
the wheel cyl i nder. Ti ghten the tube nut to a torque
of 17 N·m (145 i n. l bs.).
(6) Attach the parki ng brake cabl e to the parki ng
brake actuator.
(7) I nstal l the rear brake shoe assembl i es on the
brake support pl ate.
(8) I nstal l the rear hub and beari ng assembl y on
the spi ndl e. I nstal l a new hub and beari ng retai ni ng
nut (Fi g. 91). Ti ghten the retai ni ng nut to a torque of
217 N·m (160 ft. l bs.). I nstal l dust cap.
(9) I nstal l the brake drum.
(10) I nstal l the wheel and ti re assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(11) Adjust the rear brake shoes. Refer to
ADJUSTMENTS i n thi s secti on of thi s servi ce man-
ual group.
(12) Lower the vehi cl e.
(13) Remove the brake pedal hol di ng tool .
(14) Bl eed the wheel cyl i nder as necessary. Refer
to BASE BRAKE BLEEDI NG i n the SERVI CE PRO-
CEDURES secti on i n thi s servi ce manual group.
(15) Road test the vehi cl e to make sure the brakes
operate correctl y.
Fig. 90 Hub And Bearing Dust Cap
1 – HUB/BEARING ASSEMBLY
2 – DUST CAP
Fig. 91 Rear Hub And Bearing Retaining Nut
1 – RETAINING NUT
2 – SPINDLE
3 – HUB/BEARING ASSEMBLY
Fig. 92 Removing Park Brake Cable From Support
Plate
1 – WRENCH
2 – CABLE HOUSING RETAINER
3 – PARK BRAKE CABLE
4 – SUPPORT PLATE
PL BRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)
PARKING BRAKE LEVER
WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 25
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.
WARNING: WHEN REPAIRS TO THE PARKING
BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER ADJUSTMENT MECHANISM CAN BE
LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.
REMOVAL
(1) Bl ock the ti re and wheel s so the vehi cl e does
not move once the vehi cl e parki ng brake l ever i s
rel eased.
(2) Ful l y appl y the parki ng brake l ever, then shi ft
the transmi ssi on i nto neutral .
(3) Remove the screws attachi ng the center con-
sol e, then remove the center consol e.
(4) Lower the parki ng brake l ever handl e to the
rel eased posi ti on.
(5) Grasp the parki ng brake l ever output cabl e by
hand and pul l upward. Conti nue pul l i ng on the cabl e
unti l a pi n punch can be i nserted through the hol e i n
the l ever mechani sm sector gear and the hol e i n the
ri ght si de of i ts mounti ng bracket (Fi g. 93). Thi s wi l l
l ock the parki ng brake automati c adjustment mecha-
ni sm i n pl ace and take tensi on off the parki ng brake
cabl es.
(6) Remove both rear parki ng brake cabl es from
the parki ng brake cabl e equal i zer (Fi g. 94).
(7) Remove the wi ri ng harness el ectri cal connector
from the parki ng brake warni ng l amp swi tch on the
parki ng brake l ever (Fi g. 95).
(8) Remove the two nuts attachi ng the parki ng
brake l ever to the vehi cl e (Fi g. 95).
(9) Remove the parki ng brake l ever from the vehi -
cl e.
Fig. 93 Pin Punch Installed
1 – PARKING BRAKE LEVER
2 – PIN PUNCH
3 – OUTPUT CABLE
Fig. 94 Parking Brake Cables At Equalizer
1 – LEVER OUTPUT CABLE
2 – EQUALIZER
3 – REAR PARKING BRAKE CABLES
5 - 48 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Pl ace the parki ng brake l ever on the mounti ng
studs on the vehi cl e fl oor. I nstal l and ti ghten the two
mounti ng nuts to a torque of 28 N·m (250 i n. l bs.)
(Fi g. 95).
(2) Connect the wi ri ng harness el ectri cal connector
on the parki ng brake warni ng l amp swi tch (Fi g. 95).
(3) I nstal l both rear park brake cabl es i nto the
equal i zer on the parki ng brake l ever output cabl e
(Fi g. 94).
(4) Ensure that the parki ng brake cabl es are cor-
rectl y i nstal l ed on the equal i zer and al i gned wi th the
cabl e track on the parki ng brake l ever.
NOTE: The parking brake lever can only be in the
released position when releasing the automatic
adjuster.
(5) Keepi ng your hands cl ear of the automati c
adjuster sector and pawl area, fi rml y grasp the park-
i ng brake l ever pi n punch (or l ocki ng pi n i f a new
mechani sm has been i nstal l ed) (Fi g. 93), then qui ckl y
remove i t from the parki ng brake l ever mechani sm.
Thi s wi l l al l ow the park brake l ever mechani sm to
automati cal l y adjust the parki ng brake cabl es.
(6) Cycl e the parki ng brake l ever once to posi ti on
the parki ng brake cabl es, then return the parki ng
brake l ever i ts rel eased posi ti on.
(7) Check the rear wheel s of the vehi cl e. They
shoul d rotate freel y wi thout draggi ng wi th the l ever
i n i ts rel eased posi ti on.
(8) Ful l y appl y the parki ng brake l ever.
(9) I nstal l the center consol e and i ts mounti ng
screws.
(10) Remove the bl ocks from the ti res and wheel s.
PARKING BRAKE CABLE (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
The procedure bel ow appl i es to ei ther of the two
rear parki ng brake cabl es.
REMOVAL
(1) Bl ock the ti re and wheel s so the vehi cl e does
not move once the vehi cl e parki ng brake l ever i s
rel eased.
(2) Ful l y appl y the parki ng brake l ever, then shi ft
the transmi ssi on i nto neutral .
(3) Remove the screws attachi ng the center con-
sol e, then remove the center consol e.
(4) Lower the parki ng brake l ever handl e to the
rel eased posi ti on.
(5) Grasp the parki ng brake l ever output cabl e by
hand and pul l upward. Conti nue pul l i ng on the cabl e
unti l a pi n punch can be i nserted through the hol e i n
the l ever mechani sm sector gear and the hol e i n the
ri ght si de of i ts mounti ng bracket (Fi g. 93). Thi s wi l l
l ock the parki ng brake automati c adjustment mecha-
ni sm i n pl ace and take tensi on off the parki ng brake
cabl es.
(6) Remove both rear parki ng brake cabl es from
the parki ng brake cabl e equal i zer (Fi g. 94).
(7) Remove the rear seat cushi on from the vehi cl e.
(8) Fol d the rear carpeti ng forward to expose the
parki ng brake cabl es at the end of the rear fl oor.
(9) I nstal l the box end of a 1/2 i nch wrench over
the parki ng brake cabl e retai ner (Fi g. 96). Push the
wrench onto the retai ner unti l the retai ner fi ngers
are col l apsed. From under the carpeti ng, grasp the
parki ng brake cabl e housi ng and pul l cabl e strai ght
out of the bracket attached to the fl oor.
(10) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(11) Remove the rear ti re and wheel assembl y
from the vehi cl e.
(12) On vehi cl es equi pped wi th rear drum brakes,
remove the brake drum. Refer to BRAKE DRUM i n
thi s secti on of thi s servi ce manual group.
(13) On vehi cl es equi pped wi th rear di sc brakes:
• Remove the di sc brake cal i per gui de pi n bol ts,
then the cal i per from di sc brake adapter (Fi g. 97).
• Hang the cal i per out of the way usi ng a wi re
hanger or cord.
• Remove the brake rotor from the rear hub and
beari ng.
(14) Remove the dust cap from the rear hub and
beari ng.
Fig. 95 Parking Brake Lever
1 – MOUNTING NUTS
2 – PARKING BRAKE LEVER
3 – PARKING BRAKE WARNING LAMP SWITCH CONNECTOR
PL BRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)
(15) Remove the hub and beari ng retai ni ng nut
from the knuckl e spi ndl e, then remove the hub and
beari ng (Fi g. 97).
(16) On vehi cl es equi pped wi th rear di sc brakes,
remove the upper return spri ng, both shoe hol d-down
cl i ps, then spread the rear parki ng brake shoes apart
at the top enough to cl ear the shoe anchor and
remove the parki ng brake shoes as an assembl y from
the di sc brake adapter (Fi g. 98).
(17) To remove the rear parki ng brake cabl e from
the brake support pl ate on vehi cl es equi pped wi th
rear drum brakes:
• Remove the parki ng brake cabl e from the park-
i ng brake actuati ng l ever (Fi g. 99).
• Remove the actuati ng spri ng between the brake
shoe adjustment l ever and the brake shoe (Fi g. 100).
• Remove the parki ng brake cabl e from the rear
brake support pl ate. The parki ng brake cabl e can be
removed from brake support pl ate usi ng a 1/2 i nch
box wrench to compress the l ocki ng fi ngers on the
parki ng brake cabl e retai ner (Fi g. 101).
(18) To remove the rear parki ng brake cabl e from
the di sc brake adapter on vehi cl es equi pped wi th
rear di sc brakes:
• Remove the parki ng brake actuati ng l ever from
the parki ng brake cabl e (Fi g. 102).
Fig. 96 Compressing Cable Retainer
1 – CARPET ROLLED FORWARD
2 – WRENCH
3 – RIGHT REAR CABLE
4 – REAR PARKING BRAKE CABLES
5 – LEFT REAR CABLE
Fig. 97 Rear Disc Brakes
1 – DISC BRAKE CALIPER
2 – DISC BRAKE ADAPTER
3 – GUIDE PIN BOLTS
4 – HUB AND BEARING
5 – BRAKE ROTOR
6 – RETAINER CLIP
7 – DUST CAP
8 – NUT
Fig. 98 Parking Brake Shoes
1 – UPPER RETURN SPRING
2 – SHOE HOLD DOWN CLIPS
3 – ADJUSTER
4 – LOWER REAR SPRING
5 – DISC BRAKE ADAPTER
5 - 50 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
• Remove the parki ng brake cabl e from the rear
di sc brake adapter. The parki ng brake cabl e can be
removed from the di sc brake adapter usi ng a 1/2 i nch
offset box wrench to compress the l ocki ng fi ngers on
the parki ng brake cabl e retai ner (Fi g. 103).
(19) Remove the nut, then the parki ng brake cabl e
routi ng bracket from the tensi on strut mounti ng bol t
(Fi g. 104).
(20) Remove the parki ng brake cabl e and seal i ng
grommet from fl oor pan of the vehi cl e.
INSTALLATION
(1) From underneath push the parki ng brake cabl e
through the hol e i n the fl oor pan of the vehi cl e mak-
i ng sure the cabl e seal i ng grommet i s i nstal l ed i n the
fl oor pan as far as possi bl e to i nsure a good seal .
(2) Attach the parki ng brake cabl e routi ng bracket
to the tensi on strut mounti ng bol t. I nstal l and
ti ghten the mounti ng nut to a torque of 28 N·m (250
i n. l bs.).
Fig. 99 Actuator Lever
1 – PARK BRAKE ACTUATING LEVER
2 – PARK BRAKE CABLE
3 – BRAKE SHOE ASSEMBLIES
4 – REAR SPINDLE
Fig. 100 Actuating Spring
1 – BRAKE SHOE ADJUSTMENT LEVER
2 – ADJUSTMENT LEVER ACTUATING SPRING
3 – PARK BRAKE CABLE
Fig. 101 Parking Brake Cable Removal
1 – PARK BRAKE CABLE
2 – 1/2ЈЈ WRENCH
3 – REAR BRAKE SUPPORT PLATE
4 – PARK BRAKE CABLE RETAINER
Fig. 102 Parking Brake Actuator Lever
1 – SHOE ACTUATOR LEVER
2 – SHIELD MOUNTING SCREWS
3 – REAR PARKING BRAKE CABLE
PL BRAKES 5 - 51
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l the parki ng brake cabl e i nto the brake
support pl ate or the rear di sc brake adapter. Be sure
the l ocki ng fi ngers on the cabl e retai ner are
expanded once the cabl e i s pushed al l the way i nto
the support pl ate or brake adapter hol e to ensure the
cabl e i s securel y hel d i n pl ace.
(4) On vehi cl es equi pped wi th rear drum brakes:
• I nstal l the parki ng brake cabl e on the parki ng
brake cabl e actuati ng l ever (Fi g. 99).
• I nstal l the actuati ng spri ng to the brake shoe
and the brake adjustment l ever (Fi g. 100).
(5) On vehi cl es equi pped wi th rear di sc brakes:
• I nstal l the parki ng brake shoes actuator l ever on
the parki ng brake cabl e (Fi g. 102).
• I nstal l the parki ng brake shoe assembl i es on the
di sc brake adapter (Fi g. 98).
(6) I nstal l the hub and beari ng on the rear spi n-
dl e. I nstal l a new hub and beari ng retai ni ng nut.
Ti ghten the retai ni ng nut to a torque of 217 N·m
(160 ft. l bs.).
(7) I nstal l the hub and beari ng dust cap.
(8) On drum brake equi pped vehi cl es, i nstal l the
rear brake drum.
(9) On vehi cl es equi pped wi th rear di sc brakes,
i nstal l the brake rotor, then the di sc brake cal i per
(Fi g. 97). I nstal l the two cal i per gui de pi n bol ts, then
ti ghten them to a torque of 22 N·m (192 i n. l bs.).
(10) I nstal l the rear ti re and wheel assembl y.
Ti ghten al l wheel nuts to a torque of 135 N·m (100 ft.
l bs.).
(11) Lower the vehi cl e.
(12) Ensure that the seal grommet on the cabl e
that was i nstal l ed from underneath i s ful l y seated
i nto the fl oor pan.
(13) Route the parki ng brake cabl e under the car-
peti ng, up to parki ng brake cabl e retai ni ng bracket
on fl oor pan. I nstal l the parki ng brake cabl e through
the retai ni ng bracket. Push the cabl e i n unti l the
l ocki ng fi ngers on the cabl e retai ner l ock the cabl e
i nto pl ace.
(14) I nstal l the rear parki ng brake cabl es i nto the
equal i zer on the parki ng brake l ever output cabl e
(Fi g. 94).
(15) Ensure that the parki ng brake cabl es are cor-
rectl y i nstal l ed on the equal i zer and al i gned wi th the
cabl e track on the parki ng brake l ever.
NOTE: The parking brake lever can be in any posi-
tion when releasing the automatic adjuster.
(16) Keepi ng your hands cl ear of the automati c
adjuster sector and pawl area, fi rml y grasp the park-
i ng brake l ever pi n punch (or l ocki ng pi n i f a new
mechani sm has been i nstal l ed) (Fi g. 93), then qui ckl y
remove i t from the parki ng brake l ever mechani sm.
Thi s wi l l al l ow the park brake l ever mechani sm to
automati cal l y adjust the parki ng brake cabl es.
(17) Cycl e the parki ng brake l ever once to posi ti on
the parki ng brake cabl es, then return the parki ng
brake l ever i ts rel eased posi ti on.
(18) Check the rear wheel s of the vehi cl e. They
shoul d rotate freel y wi thout draggi ng wi th the l ever
i n i ts rel eased posi ti on.
(19) Reposi ti on the rear carpeti ng i nto pl ace.
(20) I nstal l the rear seat cushi on. Be sure the seat
cushi on i s ful l y i nstal l ed i n the retai ners on the fl oor
pan of the vehi cl e.
(21) Ful l y appl y the parki ng brake l ever.
Fig. 103 Parking Brake Cable Removal
1 – CABLE RETAINER
2 – OFFSET BOX WRENCH
3 – PARKING BRAKE CABLE
Fig. 104 Cable At Tension Strut
1 – TENSION STRUT MOUNTING BOLTS
2 – TENSION STRUT
3 – SPOOL BUSHING
4 – NUT
5 – PARKING BRAKE CABLE
5 - 52 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(22) I nstal l the center consol e and i ts mounti ng
screws.
(23) Remove the bl ocks from the ti res and wheel s.
PARKING BRAKE SHOES (REAR DISC BRAKE)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the rear ti re and wheel assembl y.
(3) Remove the rear di sc brake cal i per assembl y
from the brake rotor and store i t out of the way.
Refer to DI SC BRAKE SHOES (REAR) i n thi s
REMOVAL AND I NSTALLATI ON secti on of thi s ser-
vi ce manual group.
(4) Remove rear brake rotor.
(5) Remove the dust cap from the rear hub and
beari ng.
(6) Remove the rear hub and beari ng assembl y
retai ni ng nut and washer.
(7) Remove the rear hub and beari ng assembl y
from the rear spi ndl e.
(8) Remove the rear brake shoe assembl y hol d-
down cl i p (Fi g. 105).
(9) Turn the brake shoe adjuster wheel unti l the
adjuster i s at shortest l ength.
(10) Remove the adjuster assembl y from the park-
i ng brake shoe assembl i es (Fi g. 106).
(11) Remove the l ower shoe-to-shoe spri ng (Fi g.
107).
Fig. 105 Rear Brake Shoe Hold-Down Clip
1 – HOLD DOWN CLIP
Fig. 106 Parking Brake Shoe Adjuster Assembly
1 – ADJUSTER
Fig. 107 Brake Shoe Lower Return Spring
1 – LOWER SPRING
PL BRAKES 5 - 53
REMOVAL AND INSTALLATION (Continued)
(12) Pul l the rear brake shoe away from anchor.
Remove the rear brake shoe and upper return spri ng
(Fi g. 108).
(13) Remove the front brake shoe hol d-down cl i p
(Fi g. 109). Remove the front brake shoe assembl y.
INSTALLATION
(1) I nstal l the front brake shoe and secure i t i n
pl ace wi th a hol d-down cl i p (Fi g. 109).
(2) I nstal l the rear brake shoe and the upper shoe
return spri ng (Fi g. 108). Pul l the rear brake shoe
over the anchor bl ock unti l i t i s properl y l ocated on
the adapter.
(3) I nstal l the l ower shoe-to-shoe return spri ng
(Fi g. 107).
(4) I nstal l the brake shoe adjuster assembl y wi th
the star wheel towards the rear (Fi g. 106).
(5) I nstal l the rear brake shoe hol d down cl i p (Fi g.
105).
(6) Adjust the parki ng brake shoes to a di ameter
to 171 mm (6.75 i nch) (Fi g. 110).
(7) I nstal l the rear hub and beari ng assembl y on
spi ndl e.
(8) I nstal l a new hub and beari ng assembl y retai n-
i ng nut. Ti ghten the retai ni ng nut to a torque of 217
N·m (160 ft. l bs.).
(9) I nstal l the hub and beari ng dust cap.
(10) I nstal l the rear brake rotor.
(11) I nstal l rear di sc brake cal i per.
(12) I nstal l the ti re and wheel assembl y. Ti ghten
the wheel mounti ng nuts to a torque of 135 N·m (100
ft. l bs.).
(13) Repeat the above procedure to the parki ng
brake shoes on the other si de of the vehi cl e.
Fig. 108 Brake Shoe and Upper Spring
1 – UPPER SPRING
2 – HOLD DOWN CLIP
3 – REAR PARKING BRAKE SHOE
Fig. 109 Front Hold Down Clip And Brake Shoe
1 – FRONT BRAKE SHOE ASSEMBLY
2 – HOLD DOWN CLIP
Fig. 110 Measuring Brake Shoes
1 – REAR PARKING BRAKE SHOES
2 – BRAKE SHOE GAUGE
5 - 54 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(14) Adjust the parki ng brake shoes as necessary.
Refer to ADJUSTMENTS i n thi s secti on of thi s ser-
vi ce manual group.
(15) Lower the vehi cl e.
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER (FRONT AND REAR)
Before di sassembl i ng the brake cal i per, cl ean and
i nspect i t. Refer to CLEANI NG AND I NSPECTI ON
i n thi s secti on of thi s servi ce manual group.
CALIPER GUIDE PIN BUSHING
REMOVAL
(1) Wi th one hand, push the gui de pi n bushi ng
sl eeve towards the back of the cal i per, and at the
same ti me, pul l the sl eeve out the back of the cal i per
and bushi ng (Fi g. 111).
(2) Usi ng your fi ngers, col l apse one si de of the rub-
ber gui de pi n bushi ng. Pul l the gui de pi n bushi ng out
the other si de of the brake cal i per mounti ng boss
(Fi g. 112).
INSTALLATION
(1) Fol d the gui de pi n bushi ng i n hal f l engthwi se
at the sol i d mi ddl e secti on (Fi g. 113).
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
Fig. 111 Removing Sleeve From Bushing
1 – CALIPER
2 – SLEEVE
3 – BUSHING
Fig. 112 Removing Bushing From Caliper
1 – CALIPER
2 – BUSHING
Fig. 113 Folded Caliper Guide Pin Bushing
1 – CALIPER GUIDE PIN BUSHING
PL BRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)
(2) I nsert the fol ded bushi ng i nto the cal i per
mounti ng boss usi ng your fi ngers (Fi g. 114).
(3) Unfol d the bushi ng usi ng your fi ngers or a
wooden dowel unti l the bushi ng i s ful l y seated i nto
the cal i per housi ng. The bushi ng fl anges shoul d be
seated evenl y on both si des of the bushi ng hol e (Fi g.
115).
(4) Lubri cate the i nsi de surfaces of the bushi ng
usi ng Mopar௡ Di el ectri c Grease or an equi val ent.
(5) I nstal l the gui de pi n sl eeve i nto one end of
bushi ng unti l the seal area of bushi ng i s past the
seal groove i n the sl eeve (Fi g. 116).
(6) Hol di ng the convol uted boot on the opposi te
end of the bushi ng, push the steel sl eeve through the
bushi ng unti l the bushi ng boot i s ful l y seated i nto
the seal groove on that end of sl eeve (Fi g. 116).
I nstal l the other end bushi ng boot i nto the groove on
that end of the bushi ng sl eeve.
(7) Veri fy both ends of the bushi ng are seated i n
the sl eeve groves (Fi g. 117). When the sl eeve i s
seated properl y i nto the bushi ng, the sl eeve/bushi ng
can be hel d between your fi ngers and easi l y sl i d back
and forth wi thout the bushi ng unseati ng from the
sl eeve groove.
Fig. 114 Installing Caliper Guide Pin Bushing
1 – CALIPER
2 – BUSHING
Fig. 115 Bushing Correctly Installed In Caliper
1 – BUSHING
2 – CALIPER
3 – BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED
AROUND CALIPER BUSHING BORES.
Fig. 116 Installing Sleeve In Bushing
1 – CALIPER
2 – SLEEVE
3 – BUSHING
5 - 56 BRAKES PL
DISASSEMBLY AND ASSEMBLY (Continued)
CALIPER PISTON AND SEALS
CALIPER PISTON REMOVAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle’s brake system.
(1) Fol l owi ng the removal procedure i n DI SC
BRAKE SHOES found i n thi s secti on, remove the
cal i per from the brake rotor and hang the assembl y
on a wi re hook away from rotor and body of the vehi -
cl e so brake fl ui d cannot get on these components.
Remove the brake shoes, and pl ace a smal l pi ece of
wood between the pi ston and cal i per fi ngers.
(2) Careful l y depress the brake pedal to hydraul i -
cal l y push pi ston out of i ts bore. Once compl eted,
appl y and hol d down the brake pedal to any posi ti on
beyond the fi rst i nch of pedal travel usi ng a brake
pedal hol di ng tool . Thi s wi l l prevent the fl ui d i n the
master cyl i nder reservoi r from compl etel y drai ni ng
out.
(3) Di sconnect the brake fl ui d fl ex hose from the
cal i per assembl y and remove i t from the vehi cl e.
CALIPER SEAL REMOVAL
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(1) To di sassembl e the cal i per, mount i t i n a vi se
equi pped wi th protecti ve jaws.
(2) Remove the pi ston dust boot from the cal i per
and di scard (Fi g. 118).
NOTE: Do not use a screw driver or other metal
tool for seal removal. Using such tools can scratch
the bore or leave burrs on the seal groove edges.
(3) Usi ng a soft tool such as a pl asti c tri m sti ck,
work the pi ston seal out of i ts groove i n cal i per pi s-
ton bore (Fi g. 119). Di scard the ol d seal .
(4) Cl ean the pi ston bore and dri l l ed passage ways
usi ng al cohol or a sui tabl e sol vent. Wi pe i t dry usi ng
onl y a l i nt-free cl oth.
(5) I nspect the pi ston bore for scori ng or pi tti ng.
Bores that show l i ght scratches or corrosi on can usu-
al l y be cl eared of the l i ght scratches or corrosi on
usi ng crocus cl oth. Bores that have deep scratches or
scori ng shoul d be honed. Use Cal i per Hone, Speci al
Tool C-4095, or the equi val ent to hone the bore. Do
Fig. 117 Correctly Installed Guide Pin Sleeve And
Bushing
1 – CALIPER
2 – BUSHING
3 – SLEEVE
Fig. 118 Removing Caliper/Piston Dust Boot
1 – CALIPER
2 – SCREWDRIVER
3 – BOOT
PL BRAKES 5 - 57
DISASSEMBLY AND ASSEMBLY (Continued)
not over-hone the bore. Don not i ncrease the di ame-
ter of the bore more than 0.0254 mm (0.001 i nch)
(Fi g. 120). I f the bore does not cl ean up wi thi n thi s
speci fi cati on, a new cal i per housi ng shoul d be
i nstal l ed.
NOTE: During the honing procedure, coat the
stones and bore with brake fluid. After honing the
bore, carefully clean the seal and boot grooves with
a stiff non-metallic rotary brush. Use extreme care
in cleaning the caliper after honing. Remove all dirt
and grit by flushing the caliper bore with fresh
clean brake fluid; wipe it dry with a clean, lint free
cloth and then clean it a second time.
(6) I nspect the cal i per pi ston for pi tti ng, scratches,
or any physi cal damage. Repl ace the pi ston i f there i s
evi dence of scratches, pi tti ng or physi cal damage.
CALIPER SEAL AND PISTON INSTALLATION
NOTE: Never use an old piston seal.
(1) Di p the new pi ston seal i n cl ean brake fl ui d
and i nstal l i t i n the groove of the cal i per bore. The
seal shoul d be started at one area of the groove and
gentl y worked around and i nto the groove (Fi g. 121)
usi ng onl y your cl ean fi ngers to seat i t.
(2) Coat the new pi ston boot wi th cl ean brake fl ui d
l eavi ng a generous amount i nsi de the boot.
(3) Posi ti on the dust boot over the pi ston after
coati ng i t wi th brake fl ui d.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
Fig. 119 Removing Piston Seal
1 – PLASTIC TRIM STICK
2 – CALIPER
3 – PISTON SEAL GROOVE
4 – PISTON SEAL
Fig. 120 Honing Brake Caliper Piston Bore
1 – CALIPER
2 – CALIPER BORE
3 – SPECIAL TOOL C-4095
Fig. 121 Installing New Piston Seal
1 – CALIPER
2 – PISTON SEAL
3 – SEAL GROOVE
5 - 58 BRAKES PL
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l pi ston i nto cal i per bore pushi ng i t past
the pi ston seal unti l i t bottoms i n the cal i per bore
(Fi g. 122).
(5) Posi ti on the dust boot i nto the counterbore of
the cal i per assembl y pi ston bore.
(6) Usi ng a hammer and I nstal l er, Speci al Tool
C-4689, and Handl e, Speci al Tool C-4171, dri ve the
boot i nto the counterbore of the cal i per (Fi g. 123).
(7) I nstal l the brake shoes.
(8) Rei nstal l the cal i per on the vehi cl e and bl eed
the brakes as necessary. Fol l ow the i nstal l ati on pro-
cedure found i n DI SC BRAKE CALI PER i n the
REMOVAL AND I NSTALLATI ON secti on i n thi s sec-
ti on of thi s servi ce manual group.
CLEANING AND INSPECTION
BRAKE TUBES AND HOSES
Fl exi bl e rubber hose i s used at both front and rear
brakes. I nspecti on of brake hoses shoul d be per-
formed whenever the brake system i s servi ced and
every 7,500 mi l es or 12 months, whi chever comes
fi rst (every engi ne oi l change). I nspect hydraul i c
brake hoses for severe surface cracki ng, scuffi ng,
worn spots or physi cal damage. I f the fabri c casi ng of
the rubber hose becomes exposed due to cracks or
abrasi ons i n the rubber hose cover, the hose shoul d
be repl aced i mmedi atel y. Eventual deteri orati on of
the hose can take pl ace wi th possi bl e burst fai l ure.
Faul ty i nstal l ati on can cause twi sti ng, resul ti ng i n
wheel , ti re, or chassi s i nterference.
The steel brake tubi ng shoul d be i nspected peri od-
i cal l y for evi dence of corrosi on, physi cal damage or
contact wi th movi ng or hot components of the vehi -
cl e.
DISC BRAKES (FRONT)
BRAKE SHOES
Cl ean the front brake shoes and cal i pers wi th a
water-dampened cl oth or wi th a brake cl eaner. Do
not use a petrol eum based product.
I f a vi sual i nspecti on does not adequatel y deter-
mi ne the condi ti on of the l i ni ng, a physi cal check wi l l
be necessary.
Remove the front di sc brake shoes. Refer to DI SC
BRAKE SHOES i n the REMOVAL AND I NSTALLA-
TI ON secti on i n thi s secti on of thi s servi ce manual
group.
The combi ned brake shoe and l i ni ng materi al
thi ckness shoul d be measured at the thi nnest part of
the assembl y.
When a set of brake shoes are worn to a total
thi ckness of approxi matel y 7.95 mm (5/16 i nch) or
l ess, they shoul d be repl aced.
Repl ace both brake shoe assembl i es (i nboard and
outboard). I t i s necessary that both front wheel sets
be repl aced whenever brake shoe assembl i es on
ei ther si de are repl aced.
Fig. 122 Installing Piston Into Caliper Bore
1 – BOOT
2 – PISTON
3 – CALIPER
Fig. 123 Installing Dust Boot In Caliper Counterbore
1 – HAMMER
2 – SPECIAL TOOL C-4171
3 – SPECIAL TOOL C-4689
4 – CALIPER
PL BRAKES 5 - 59
DISASSEMBLY AND ASSEMBLY (Continued)
I f the brake shoe assembl i es do not requi re
repl acement, rei nstal l the assembl i es maki ng sure
each brake shoe i s returned to the ori gi nal posi ti on.
Refer to DI SC BRAKE SHOES i n the REMOVAL
AND I NSTALLATI ON secti on i n thi s secti on of thi s
servi ce manual group.
CALIPER INSPECTION
Check for brake fl ui d l eaks i n and around the boot
area. Check for any ruptures, bri ttl eness or damage
to the pi ston dust boot. I f the boot i s damaged, or a
fl ui d l eak i s vi si bl e, di sassembl e the cal i per assembl y
and i nstal l a new seal and boot, and a pi ston i f i t i s
scored. Refer to DI SC BRAKE CALI PER i n the DI S-
ASSEMBLY AND ASSEMBLY secti on i n thi s secti on
of thi s servi ce manual group.
Check the gui de pi n dust boots to determi ne i f they
are i n good condi ti on. Repl ace i f they are damaged,
dry, or found to be bri ttl e. Refer to DI SC BRAKE
CALI PER i n the DI SASSEMBLY AND ASSEMBLY
secti on i n thi s secti on of thi s servi ce manual group.
DISC BRAKES (REAR)
BRAKE SHOES
Cl ean the rear brake shoes and cal i pers wi th a
water-dampened cl oth or wi th a brake cl eaner. Do
not use a petrol eum based product.
I f a vi sual i nspecti on does not adequatel y deter-
mi ne the condi ti on of the l i ni ng, a physi cal check wi l l
be necessary.
Remove the rear di sc brake shoes. Refer to DI SC
BRAKE SHOES i n the REMOVAL AND I NSTALLA-
TI ON secti on i n thi s secti on of thi s servi ce manual
group.
The combi ned brake shoe and l i ni ng materi al
thi ckness shoul d be measured at the thi nnest part of
the assembl y.
When a set of brake shoes are worn to a total
thi ckness of approxi matel y 7.0 mm (9/32 i nch) or
l ess, they shoul d be repl aced.
Repl ace both brake shoe assembl i es (i nboard and
outboard). I t i s necessary that both front wheel sets
be repl aced whenever brake shoe assembl i es on
ei ther si de are repl aced.
I f the brake shoe assembl i es do not requi re
repl acement, rei nstal l the assembl i es maki ng sure
each brake shoe i s returned to the ori gi nal posi ti on.
Refer to DI SC BRAKE SHOES i n the REMOVAL
AND I NSTALLATI ON secti on i n thi s secti on of thi s
servi ce manual group.
CALIPER INSPECTION
Check for brake fl ui d l eaks i n and around the boot
area. Check for any ruptures, bri ttl eness or damage
to the pi ston dust boot. I f the boot i s damaged, or a
fl ui d l eak i s vi si bl e, di sassembl e the cal i per assembl y
and i nstal l a new seal and boot, and a pi ston i f i t i s
scored. Refer to DI SC BRAKE CALI PER i n the DI S-
ASSEMBLY AND ASSEMBLY secti on i n thi s secti on
of thi s servi ce manual group.
Check the gui de pi n dust boots to determi ne i f they
are i n good condi ti on. Repl ace i f they are damaged,
dry, or found to be bri ttl e. Refer to DI SC BRAKE
CALI PER i n the DI SASSEMBLY AND ASSEMBLY
secti on i n thi s secti on of thi s servi ce manual group.
DRUM BRAKES (REAR)
BRAKE SHOES
Cl ean the rear brake shoes and spri ngs wi th a
water-dampened cl oth or wi th a brake cl eaner. Do
not use a petrol eum based product.
Rear brake shoe l i ni ng shoul d show contact across
the enti re wi dth of the l i ni ng and al so from the heel
to the toe of the l i ni ng. Repl ace the shoes i f noted
otherwi se.
Brake shoes wi th l ack of contact at the toe or heel
of the brake shoe l i ni ng may be i mproperl y ground.
Cl ean and i nspect the brake support pl ate and
shoe adjuster screw. Appl y a thi n coat of Mopar௡
Mul ti -Purpose Lubri cant or equi val ent to the threads
of the sel f-adjuster (Fi g. 124). Repl ace the adjuster
screw i f i t i s corroded.
NOTE: Adjuster screws are different side-to-side.
Left side adjuster screws have left-hand threads
and right side adjuster screws have right-handed
threads.
I f the ol d brake shoe return or hol d down spri ngs
have overheated or are damaged, repl ace them. Over-
heati ng i ndi cati ons are pai nt di scol orati on or di s-
torted end coi l s.
Fig. 124 Adjuster Screw And Lever (Typical)
1 – OUTBOARD FORWARD
2 – SELF ADJUSTER
3 – OUTBOARD REAR
4 – SELF ADJUSTER LEVER
5 - 60 BRAKES PL
CLEANING AND INSPECTION (Continued)
WHEEL CYLINDER
Wi th the brake drums removed, i nspect the wheel
cyl i nder boots for evi dence of a brake fl ui d l eak.
Vi sual l y check the boots for cuts, tears, or heat
cracks. I f any of these condi ti ons exi st, the wheel cyl -
i nders shoul d be compl etel y cl eaned, i nspected and
new parts i nstal l ed.
I f a wheel cyl i nder i s l eaki ng and the brake l i ni ng
materi al i s saturated wi th brake fl ui d, the brake
shoes must be repl aced.
ADJ USTMENTS
BRAKE LAMP SWITCH
(1) Depress and hol d the brake pedal whi l e rotat-
i ng the brake l amp swi tch (Fi g. 125) i n a counter-
cl ockwi se di recti on approxi matel y 30 degrees.
(2) Pul l the swi tch rearward and remove i t from
i ts mounti ng bracket.
(3) I f necessary, di sconnect the wi ri ng harness con-
nector from the swi tch.
(4) Hol d the brake l amp swi tch fi rml y i n one hand.
Usi ng the other hand, pul l outward on the pl unger of
the swi tch unti l i t has ratcheted out to i ts ful l y
extended posi ti on.
(5) I f di sconnected, connect the wi ri ng harness
connector to the stop l amp swi tch.
(6) Mount the brake l amp swi tch i nto the bracket
usi ng the fol l owi ng procedure:
• Depress the brake pedal as far down as possi bl e.
• I nstal l the swi tch i n i ts bracket by al i gni ng the
i ndex tab on the swi tch wi th the sl ot i n the mounti ng
bracket.
• When the swi tch i s ful l y seated i n i ts bracket,
rotate the swi tch cl ockwi se approxi matel y 30° to l ock
the swi tch i nto pl ace.
CAUTION: Do not use excessive force when pulling
back on the brake pedal to adjust the brake lamp
switch. If too much force is used, the switch or
striker can be damaged.
(7) Gentl y pul l back on the brake pedal unti l the
pedal stops movi ng. Thi s wi l l ratchet the swi tch
pl unger backward to the correct adjustment posi ti on.
(8) Check the stop l amps to veri fy that they are
operati ng properl y and not stayi ng on when the
pedal i s i n the rel eased posi ti on.
DRUM BRAKE SHOES
(1) Veri fy the parki ng brake l ever i s i n the ful l y
rel eased posi ti on.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group fro the
proper l i fti ng procedure.
(3) Remove the rear brake adjusti ng hol e rubber
pl ug from the rear brake shoe support pl ate (Fi g.
126).
Fig. 125 Brake Lamp Switch
1 – SWITCH
2 – CLIP
3 – BRAKE PEDAL
4 – CONNECTOR
Fig. 126 Rear Brake Adjusting Hole Plug
1 – REAR BRAKE SUPPORT PLATE
2 – REAR STRUT
3 – BRAKE ADJUSTING HOLE PLUG
PL BRAKES 5 - 61
CLEANING AND INSPECTION (Continued)
(4) I nsert a brake adjustment tool , or a screw-
dri ver, through the adjusti ng hol e i n support pl ate
and agai nst the star wheel of the adjuster screw.
Move the handl e of tool downward to adjust the
brake drag. Rotate the ti re and wheel assembl y whi l e
adjusti ng the adjuster screw. Conti nue to adjust the
shoes unti l a sl i ght drag i s noti ced when the ti re and
wheel assembl y i s rotated.
NOTE: In the event the brake shoes are over-ad-
justed, the adjuster can be backed off using the fol-
lowing step. If not, proceed to step 6.
(5) I f the shoes are i n the over-adjusted posi ti on,
i nsert a thi n screwdri ver i nto brake adjusti ng hol e
and push back the adjusti ng l ever out of engagement
wi th star wheel (Fi g. 127). Take care not to bend the
adjusti ng l ever. Whi l e hol di ng the adjusti ng l ever out
of engagement wi th star wheel , back off the star
wheel unti l the ti re and wheel assembl y i s free to
turn wi thout draggi ng. Repeat the adjustment proce-
dure.
(6) I nstal l adjusti ng hol e rubber pl ug (Fi g. 126).
(7) Repeat the above adjustment procedure to the
other si de brakes.
(8) Appl y and rel ease the park brake l ever one
ti me after the adjustment process i s compl eted so the
parki ng brakes can readjust themsel ves to the new
brake shoe adjustment.
PARKING BRAKE SHOES (REAR DISC BRAKES)
NOTE: The parking brake shoes used in the drum-
in-hat park brake system do not automatically
adjust to compensate for brake shoe lining wear.
Therefore, it is necessary to manually adjust the
parking brake shoes.
(1) Veri fy the parki ng brake l ever i s i n the
rel eased posi ti on.
(2) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(3) Remove the rubber pl ug from the adjusti ng
hol e i n the di sc brake cal i per adapter.
(4) Adjust the parki ng brakes. Use the fi rst bul l et
poi nt for the adjustment of the l eft si de parki ng
brake shoes. Use the second bul l et poi nt for the
adjustment of the ri ght si de parki ng brake shoes.
• I nsert a medi um si ze screwdri ver through
adjustment hol e i n the l eft backi ng pl ate. Posi ti on
the screwdri ver agai nst the star wheel on the park-
i ng brake shoe adjuster. Usi ng the screwdri ver,
rotate the star wheel downward unti l a sl i ght drag i s
noti ced when turni ng the rear ti re and wheel assem-
bl y. Then, usi ng the screwdri ver, sl owl y rotate the
star wheel upward, backi ng off the adjuster, just
enough to al l ow the rear ti re and wheel assembl y to
rotate wi thout the parki ng brake shoes draggi ng. Do
not back off the adjuster star wheel more than two
cl i cks past the poi nt of no drag. The parki ng brake
shoe-to-drum cl earance i s now properl y set.
• I nsert a medi um si ze screwdri ver through
adjustment hol e i n the ri ght backi ng pl ate. Posi ti on
the screwdri ver agai nst the star wheel on the park-
i ng brake shoe adjuster. Usi ng the screwdri ver,
rotate the star wheel upward unti l a sl i ght drag i s
noti ced when turni ng the rear ti re and wheel assem-
bl y. Then, usi ng the screwdri ver, sl owl y rotate the
star wheel downward, backi ng off the adjuster, just
enough to al l ow the rear ti re and wheel assembl y to
rotate wi thout the parki ng brake shoes draggi ng. Do
not back off the adjuster star wheel more that two
cl i cks past the poi nt of no drag. The parki ng brake
shoe-to-drum cl earance i s now properl y set.
(5) I nstal l the rubber pl ug i n the adjusti ng hol es of
the di sc brake cal i per adapter.
(6) Lower the vehi cl e unti l the rear ti res are just
cl eari ng the fl oor.
(7) Reach i nsi de the vehi cl e and ful l y appl y and
rel ease the park brakes two ti mes after adjusti ng the
parki ng brake shoes.
(8) Wi th the parki ng brake l ever i n the ful l y
appl i ed posi ti on, attempt to hand rotate each rear
ti re and wheel assembl y to ensure that the parki ng
brake shoes are worki ng.
(9) Wi th the parki ng brake l ever i n the rel eased
posi ti on, hand rotate each rear ti re and wheel assem-
bl y to ensure that the parki ng brake shoes are not
draggi ng.
Fig. 127 Backing Off Brake Adjuster Screw
1 – MEDIUM SCREWDRIVER
2 – BRAKE ADJUSTING HOLE
3 – THIN SCREWDRIVER OR WELDING ROD
5 - 62 BRAKES PL
ADJ USTMENTS (Continued)
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes . . . . . Standard
Hydraul i c System . . . . . . . Dual -Di agonal l y Spl i t
BRAKE PEDAL:
Pedal Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
POWER BRAKE BOOSTER:
Make/Type . . . . . . . . . . . . . . . . . . Bosch/Vacuum
Mounti ng Studs . . . . . . . . . . . . . . . . . . M8 x 1.25
Di aphragm Si ze/Type . . . . . . . . 205 mm Tandem
MASTER CYLINDER ASSEMBLY:
Type . . . . . . . . . . . . . . . . . . . . . . . . Dual Tandem
Body Materi al . . . . . . . . . . . Anodi zed Al umi num
Reservoi r Materi al . . . . . . . . . . . . . Pol ypropel ene
MASTER CYLINDER BORE STROKE AND
SPLIT:
Non ABS . . . . . . . . . . . . . . 22.23 mm x 34.0 mm
(0.875 i n. x 1.34 i n.)
ABS . . 23.82 mm x 34.0 mm (0.937 i n. x 1.34 i n.)
Di spl acement Spl i t . . . . . . . . . . . . . . . . . . 50 /50
MASTER CYLINDER FLUID OUTLET PORTS:
Tube Fi tti ng Type . . . . . . SAE 45° I nverted Fl are
W/ABS - Pri mary Tube Nut
Thread . . . . . . . . . . . . . . . . . . . . . . . . 7/16 i n.–24
W/ABS - Secondary Tube Nut
Thread . . . . . . . . . . . . . . . . . . . . . . . . 3/8 i n.–24
W/O ABS - Al l Tube Nut Threads . . . . 7/16 i n.–24
ABS HYDRAULIC CONTROL UNIT:
Hydraul i c Tube Fi tti ng
Type . . . . . . . . . . . . . . . . SAE 45° I nverted Fl are
Al l Tube Nut Threads . . . . . . . . . . . . 7/16 i n.–24
PROPORTIONING VALVE:
Materi al . . . . . . . . . . . . . . . . . . . . . . . Al umi num
Functi on . . . . . Hydraul i c Pressure Proporti oni ng
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts. . . . . . . . . . . . . . . 17 N·m (145 i n. l bs.)
MASTER CYLINDER:
Mounti ng Nuts . . . . . . . . . . 28 N·m (250 i n. l bs.)
POWER BRAKE BOOSTER:
Mounti ng Nuts . . . . . . . . . . 34 N·m (300 i n. l bs.)
DISC BRAKE CALIPER:
Cal i per Banjo Bol t . . . . . . . . . 48 N·m (35 ft. l bs.)
Gui de Pi n Bol ts . . . . . . . . . . 22 N·m (192 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . 15 N·m (125 i n. l bs.)
WHEEL CYLINDER (REAR):
Mounti ng Bol ts . . . . . . . . . . 13 N·m (115 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . . 10 N·m (80 i n. l bs.)
DRUM BRAKE SHOE SUPPORT PLATE
(REAR):
Mounti ng Bol ts . . . . . . . . . . . 75 N·m (55 ft. l bs.)
DISC BRAKE ADAPTER (REAR):
Mounti ng Bol ts . . . . . . . . . . . 75 N·m (55 ft. l bs.)
HUB AND BEARING (REAR):
Retai ni ng Nut . . . . . . . . . . 217 N·m (160 ft. l bs.)
PARKING BRAKE:
Lever Mounti ng Nuts . . . . . 28 N·m (250 i n. l bs.)
TIRE AND WHEEL:
Wheel Mounti ng Nut . . . . . . . . . . . 109–150 N·m
(80–110 ft. l bs.)
INTEGRATED CONTROL UNIT:
Mounti ng Bol ts . . . . . . . . . . . 11 N·m (97 i n. l bs.)
CAB Mounti ng bol ts . . . . . . . . 2 N·m (17 i n. l bs.)
Bracket-to-Frame Rai l Bol ts . . . . . . . . . . 23 N·m
(200 i n. l bs.)
WHEEL SPEED SENSOR:
Head Mounti ng bol t . . . . . . 12 N·m (105 i n. l bs.)
PL BRAKES 5 - 63
SPECIAL TOOLS
BASE BRAKE SYSTEM
Adapters, Brake Pressure 6805
Adapter, Brake Pressure 8644
Gauge Set C-4007-A
Handle, Universal C-4171
Installer, Dust Boot C-4689
Dial Indicator C-3339
Tubes, Master Cylinder Bleed 8358
5 - 64 BRAKES PL
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION . . . . . . 65
ANTILOCK BRAKE SYSTEM COMPONENTS. . . . 66
ELECTRONIC BRAKE DISTRIBUTION . . . . . . . . . 69
TRACTION CONTROL SYSTEM. . . . . . . . . . . . . . 70
HYDRAULIC CIRCUITS AND VALVE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIAGNOSIS AND TESTING
SERVICE WARNINGS AND CAUTIONS . . . . . . . . 74
ABS GENERAL DIAGNOSTICS INFORMATION . . 74
ABS WIRING DIAGRAM INFORMATION. . . . . . . . 74
ABS VEHICLE TEST DRIVE. . . . . . . . . . . . . . . . . 74
ABS ELECTRONIC DIAGNOSIS. . . . . . . . . . . . . . 75
TONE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 76
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING . . . . . . . . . . . . 77
ANTILOCK BRAKE SYSTEM BLEEDING . . . . . . . 77
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 77
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS . . . . . . . . 78
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 78
INTEGRATED CONTROL UNIT. . . . . . . . . . . . . . . 79
WHEEL SPEED SENSOR (FRONT) . . . . . . . . . . . 81
WHEEL SPEED SENSOR (REAR) . . . . . . . . . . . . 83
DISASSEMBLY AND ASSEMBLY
INTEGRATED CONTROL UNIT. . . . . . . . . . . . . . . 84
SPECIFICATIONS
TONE WHEEL RUNOUT. . . . . . . . . . . . . . . . . . . . 85
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
BRAKE FASTENER TORQUE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 85
DESCRIPTION AND OPERATION
ANTILOCK BRAKE SYSTEM OPERATION
Thi s secti on covers the physi cal and operati onal
descri pti ons, and the on-car servi ce procedures for
the Mark 20e Anti l ock Brake System (ABS) wi th
tracti on control . I t i s the onl y anti l ock brake system
avai l abl e on thi s vehi cl e.
The purpose of the anti l ock brake system i s to pre-
vent wheel l ockup under braki ng condi ti ons on vi rtu-
al l y any type of road surface. Anti l ock braki ng i s
desi rabl e because a vehi cl e that i s stopped wi thout
l ocki ng the wheel s retai ns di recti onal stabi l i ty and
some steeri ng capabi l i ty. Thi s al l ows the dri ver to
retai n greater control of the vehi cl e duri ng braki ng.
The tracti on control system reduces wheel sl i p and
mai ntai ns tracti on at the dri vi ng speeds bel ow 56
kph (35 mph) when road condi ti ons cal l for tracti on
assi stance. Refer to TRACTI ON CONTROL SYSTEM
i n thi s secti on for more i nformati on.
Vehi cl es equi pped wi th ABS use el ectroni c brake
di stri buti on (EBD) to bal ance front-to-rear braki ng
when the brakes are appl i ed i n the parti al braki ng
range. Refer to ELECTRONI C BRAKE DI STRI BU-
TI ON i n thi s secti on for more i nformati on.
There are a few performance characteri sti cs of the
Mark 20e Anti l ock Brake System that may at fi rst
seem abnormal , but i n fact are normal . These char-
acteri sti cs are descri bed bel ow.
NORMAL BRAKING
Under normal braki ng condi ti ons, the ABS func-
ti ons the same as a standard base brake system wi th
a di agonal l y spl i t master cyl i nder and conventi onal
vacuum assi st.
ABS BRAKING
ABS operati on i s avai l abl e at al l vehi cl e speeds
above 3–5 mph. I f a wheel l ocki ng tendency i s
detected duri ng a brake appl i cati on, the brake sys-
tem enters the ABS mode. Duri ng ABS braki ng,
hydraul i c pressure i n the four wheel ci rcui ts i s mod-
ul ated to prevent any wheel from l ocki ng. Each
wheel ci rcui t i s desi gned wi th a set of el ectri c sol e-
noi ds to al l ow modul ati on, al though for vehi cl e sta-
bi l i ty, both rear wheel sol enoi ds recei ve the same
el ectri cal si gnal . Wheel l ockup may be percei ved at
the very end of an ABS stop and i s consi dered nor-
mal .
Duri ng an ABS stop, the brakes hydraul i c system
i s sti l l di agonal l y spl i t. However, the brake system
pressure i s further spl i t i nto four control channel s.
Duri ng anti l ock operati on of the vehi cl e’s brake sys-
tem, the wheel s are control l ed i ndependentl y and are
on separate control channel s.
The system can bui l d, hol d and rel ease pressure at
each wheel , dependi ng on si gnal s generated by the
wheel speed sensors (WSS) at each wheel and
recei ved at the control l er anti l ock brake (CAB).
PL BRAKES 5 - 65
NOISE AND BRAKE PEDAL FEEL
Duri ng ABS braki ng, some brake pedal movement
may be fel t. I n addi ti on, ABS braki ng wi l l create
ti cki ng, poppi ng, or groani ng noi ses heard by the
dri ver. Thi s i s normal and i s due to pressuri zed fl ui d
bei ng transferred between the master cyl i nder and
the brakes. I f ABS operati on occurs duri ng hard
braki ng, some pul sati on may be fel t i n the vehi cl e
body due to fore-and-aft movement of the suspensi on
as brake pressures are modul ated.
At the end of an ABS stop, ABS i s turned off when
the vehi cl e i s sl owed to a speed of 3–4 mph. There
may be a sl i ght brake pedal drop anyti me that the
ABS i s deacti vated, such as at the end of the stop
when the vehi cl e speed i s l ess than 3 mph or duri ng
an ABS stop where ABS i s no l onger requi red. These
condi ti ons exi st when a vehi cl e i s bei ng stopped on a
road surface wi th patches of i ce, l oose gravel , or sand
on i t. Al so, stoppi ng a vehi cl e on a bumpy road sur-
face acti vates ABS because of the wheel hop caused
by the bumps.
TIRE NOISE AND MARKS
Al though the ABS system prevents compl ete wheel
l ockup, some wheel sl i p i s desi red i n order to achi eve
opti mum braki ng performance. Wheel sl i p i s defi ned
as fol l ows: 0 percent sl i p means the wheel i s rol l i ng
freel y and 100 percent sl i p means the wheel i s ful l y
l ocked. Duri ng brake pressure modul ati on, wheel sl i p
i s al l owed to reach up to 25–30 percent. Thi s means
that the wheel rol l i ng vel oci ty i s 25–30 percent l ess
than that of a free rol l i ng wheel at a gi ven vehi cl e
speed. Thi s sl i p may resul t i n some ti re chi rpi ng,
dependi ng on the road surface. Thi s sound shoul d not
be i nterpreted as total wheel l ockup.
Compl ete wheel l ockup normal l y l eaves bl ack ti re
marks on dry pavement. The ABS wi l l not l eave dark
bl ack ti re marks si nce the wheel never reaches a
ful l y l ocked condi ti on. However, ti re marks may be
noti ceabl e as l i ght patched marks.
START-UP CYCLE
When the i gni ti on i s turned on, a poppi ng sound
and a sl i ght brake pedal movement may be noti ced.
The ABS warni ng l amp wi l l al so be on for up to 5
seconds after the i gni ti on i s turned on. When the
vehi cl e i s fi rst dri ven off, a hummi ng may be heard
or fel t by the dri ver at approxi matel y 20–40 kph
(12–25 mph). Al l of these condi ti ons are a normal
functi on of ABS as the system i s performi ng a di ag-
nosi s check.
PREMATURE ABS CYCLING
Symptoms of premature ABS cycl i ng i ncl ude: cl i ck-
i ng sounds from the sol enoi d val ves; pump/motor
runni ng; and pul sati ons i n the brake pedal . Prema-
ture ABS cycl i ng can occur at any braki ng rate of the
vehi cl e and on any type of road surface. Nei ther the
red BRAKE warni ng l amp, nor the amber ABS warn-
i ng l amp, i l l umi nate and no faul t codes are stored i n
the CAB.
Premature ABS cycl i ng i s a condi ti on that needs to
be correctl y assessed when di agnosi ng probl ems wi th
the anti l ock brake system. I t may be necessary to use
a DRB scan tool to detect and veri fy premature ABS
cycl i ng.
Check the fol l owi ng common causes when di agnos-
i ng premature ABS cycl i ng: damaged tone wheel s;
i ncorrect tone wheel s; damaged steeri ng knuckl e
wheel speed sensor mounti ng bosses; l oose wheel
speed sensor mounti ng bol ts; excessi ve tone wheel
runout; or an excessi vel y l arge tone wheel -to-wheel
speed sensor ai r gap. Gi ve speci al attenti on to these
components when di agnosi ng a vehi cl e exhi bi ti ng
premature ABS cycl i ng.
After di agnosi ng the defecti ve component, repai r or
repl ace i t as requi red. When the component repai r or
repl acement i s compl eted, test dri ve the vehi cl e to
veri fy that premature ABS cycl i ng has been cor-
rected.
ANTILOCK BRAKE SYSTEM COMPONENTS
The fol l owi ng i s a detai l ed descri pti on of the
anti l ock brake system components. For i nformati on
on servi ci ng base brake system components used i n
conjuncti on wi th these components, see the BASE
BRAKE SYSTEM found at the begi nni ng of thi s ser-
vi ce manual group.
MASTER CYLINDER
A vehi cl e equi pped wi th ABS uses a di fferent mas-
ter cyl i nder than a vehi cl e that i s not equi pped wi th
ABS. Vehi cl es equi pped wi th ABS use a center port
master cyl i nder wi th onl y two outl et ports (Fi g. 1).
The brake tubes from the pri mary and secondary
outl et ports on the master cyl i nder go di rectl y to the
i ntegrated control uni t (I CU).
The master cyl i nder mounts to the power brake
booster i n the same manner a non-ABS master cyl i n-
der does.
INTEGRATED CONTROL UNIT (ICU)
The hydraul i c control uni t (HCU) and the control -
l er anti l ock brake (CAB) used wi th thi s anti l ock
brake system are combi ned (i ntegrated) i nto one
uni t, whi ch i s cal l ed the i ntegrated control uni t (I CU)
(Fi g. 2). The I CU i s l ocated on the dri ver’s si de of the
vehi cl e, and i s mounted to the l eft front frame rai l
bel ow the master cyl i nder (Fi g. 1).
5 - 66 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
The ABS wi th tracti on control I CU consi sts of the
fol l owi ng components: the CAB, ei ght (bui l d/decay)
sol enoi d val ves (four i nl et val ves and four outl et
val ves), two hydraul i c shuttl e val ves, two tracti on
control val ves, val ve bl ock, fl ui d accumul ators, a
pump, and an el ectri c pump/motor.
The repl aceabl e components of the I CU are the
HCU and the CAB. No attempt shoul d be made to
servi ce any components found i nsi de of the HCU or
CAB.
CONTROLLER ANTILOCK BRAKE (CAB)
The control l er anti l ock brake (CAB) i s a mi cropro-
cessor-based devi ce whi ch moni tors the ABS system
duri ng normal braki ng and control s i t when the vehi -
cl e i s i n an ABS stop. The CAB i s mounted to the
bottom of the HCU (Fi g. 2). The CAB uses a 25-way
el ectri cal connector on the vehi cl e wi ri ng harness.
The power source for the CAB i s through the i gni ti on
swi tch i n the RUN or ON posi ti on. The CAB i s on
the PCI bus.
The pri mary functi ons of the (CAB) are to:
(1) moni tor the anti l ock brake system for proper
operati on.
(2) detect wheel l ocki ng or wheel sl i ppi ng tenden-
ci es by moni tori ng the speed of al l four wheel s of the
vehi cl e.
(3) control fl ui d modul ati on to the wheel brakes
whi l e the system i s i n an ABS mode or the tracti on
control system i s acti vated.
(4) store di agnosti c i nformati on.
(5) provi de communi cati on to the DRB scan tool
whi l e i n di agnosti c mode.
The CAB constantl y moni tors the anti l ock brake
system for proper operati on. I f the CAB detects a
faul t, i t wi l l send a message to the mechani cal i nstu-
ment cl uster (MI C) i nstructi ng i t to turn on the
amber ABS warni ng l amp and di sabl e the anti l ock
braki ng system. The normal base braki ng system wi l l
remai n operati onal .
The CAB conti nuousl y moni tors the speed of each
wheel through the si gnal s generated by the wheel
speed sensors to determi ne i f any wheel i s begi nni ng
to l ock. When a wheel l ocki ng tendency i s detected,
the CAB commands the CAB command coi l s to actu-
ate. The CAB command coi l s then open and cl ose the
val ves i n the HCU that modul ate brake fl ui d pres-
sure i n some or al l of the hydraul i c ci rcui ts. The CAB
conti nues to control pressure i n i ndi vi dual hydraul i c
ci rcui ts unti l a l ocki ng tendency i s no l onger present.
The CAB contai ns a sel f-di agnosti c program that
moni tors the anti l ock brake system for system faul ts.
When a faul t i s detected, the amber ABS warni ng
l amp i s turned on and the faul t di agnosti c troubl e
code (DTC) i s then stored i n a di agnosti c program
memory. These DTC’s wi l l remai n i n the CAB mem-
ory even after the i gni ti on has been turned off. The
DTC’s can be read and cl eared from the CAB mem-
ory by a techni ci an usi ng the DRB scan tool . I f not
cl eared wi th a DRB scan tool , the faul t occurrence
and DTC wi l l be automati cal l y cl eared from the CAB
memory after the i denti cal faul t has not been seen
duri ng the next 3,500 mi l es of vehi cl e operati on.
Fig. 1 Master Cylinder And ICU
1 – PRIMARY BRAKE TUBE
2 – MASTER CYLINDER
3 – SECONDARY BRAKE TUBE
4 – ABS ICU
Fig. 2 Integrated Control Unit (ICU)
1 – HCU
2 – PUMP/MOTOR
3 – CAB
PL BRAKES 5 - 67
DESCRIPTION AND OPERATION (Continued)
CONTROLLER ANTILOCK BRAKE INPUTS
• wheel speed sensors (four)
• stop l amp swi tch
• i gni ti on swi tch
• system rel ay vol tage
• ground
• tracti on control l amp
• di agnosti c communi cati on (PCI )
CONTROLLER ANTILOCK BRAKE OUTPUTS
• amber ABS warni ng l amp actuati on (through
MI C)
• red BRAKE warni ng l amp actuati on (through
MI C)
• tracti on control l amp actuati on (through MI C)
• di agnosti c communi cati on. (PCI )
HYDRAULIC CONTROL UNIT (HCU)
The hydraul i c control uni t (HCU) i s mounted to
the CAB as part of the I CU (Fi g. 2). The HCU con-
trol s the fl ow of brake fl ui d to the brakes usi ng a
seri es of val ves and accumul ators. A pump/motor i s
mounted on the HCU to suppl y bui l d pressure to the
brakes duri ng an ABS stop.
VALVES AND SOLENOIDS
The val ve bl ock contai ns four i nl et val ves and four
outl et sol enoi d val ves. The i nl et val ves are spri ng-
l oaded i n the open posi ti on and the outl et val ves are
spri ng-l oaded i n the cl osed posi ti on duri ng normal
braki ng. The fl ui d i s al l owed to fl ow from the master
cyl i nder to the wheel brakes.
Duri ng an ABS stop, these val ves cycl e to mai ntai n
the proper sl i p rati o for each wheel . The i nl et val ve
cl oses preventi ng further pressure i ncrease and the
outl et val ve opens to provi de a path from the wheel
brake to the HCU accumul ators and pump/motor.
Thi s rel eases (decays) pressure from the wheel brake,
thus rel easi ng the wheel from excessi ve sl i ppage.
Once the wheel i s no l onger sl i ppi ng, the outl et val ve
i s cl osed and the i nl et val ve i s opened to reappl y
(bui l d) pressure.
There are four other val ves i n the HCU. These four
remai ni ng val ves are used for tracti on control . Two
tracti on control (TC) val ves, mounted i n the HCU
val ve bl ock, are normal l y i n the open posi ti on and
cl ose onl y when the tracti on control i s appl i ed. There
are al so two shuttl e val ves whi ch control pressure
return to the master cyl i nder under ABS and tracti on
control condi ti ons.
These TC val ves are used to i sol ate the rear (non-
dri vi ng) wheel s of the vehi cl e from the hydraul i c
pressure that the HCU pump/motor i s sendi ng to the
front (dri vi ng) wheel s when tracti on control i s bei ng
appl i ed. The rear brakes need to be i sol ated from the
master cyl i nder when tracti on control i s bei ng
appl i ed so the rear wheel s do not drag. For more
i nformati on on the TC and shuttl e val ves, see TRAC-
TI ON CONTROL SYSTEM i n thi s secti on.
BRAKE FLUID ACCUMULATORS
There are two fl ui d accumul ators i n the HCU: one
for the pri mary hydraul i c ci rcui t, and one for the sec-
ondary hydraul i c ci rcui t. Each hydraul i c ci rcui t uses
a 3 cc accumul ator.
The fl ui d accumul ators temporari l y store brake
fl ui d that i s removed from the wheel brakes duri ng
an ABS cycl e. Thi s stored fl ui d i s used by the pump/
motor to provi de bui l d pressure for the brake hydrau-
l i c system. When the anti l ock stop i s compl ete, the
accumul ators are drai ned by the pump/motor.
There are two noi se dampeni ng chambers i n the
HCU on thi s vehi cl e equi pped wi th tracti on control .
PUMP/MOTOR
There are two pump assembl i es i n the HCU: one
for the pri mary hydraul i c ci rcui t, and one for the sec-
ondary hydraul i c ci rcui t. Both pumps are dri ven by a
common el ectri c motor (Fi g. 2). Thi s DC-type motor
i s i ntegral to the HCU and i s control l ed by the CAB.
The pump/motor provi des the extra amount of
brake fl ui d needed duri ng anti l ock braki ng. Brake
fl ui d i s rel eased to the accumul ators when the outl et
val ve i s opened duri ng an anti l ock stop. The pump
mechani sm consi sts of two opposi ng pi stons operated
by an eccentri c camshaft. I n operati on, these pi stons
are used to purge fl ui d from the accumul ators back
i nto the master cyl i nder ci rcui ts. When the anti l ock
stop i s compl ete, the pump/motor drai ns the accumu-
l ators.
The pump motor i s al so used to bui l d pressure
when the system goes i nto tracti on control mode. For
more i nformati on, refer to TRACTI ON CONTROL
SYSTEM i n thi s secti on.
The CAB may turn on the pump/motor when an
anti l ock stop i s detected. The pump/motor conti nues
to run duri ng the anti l ock stop and i s turned off after
the stop i s compl ete. Under some condi ti ons, the
pump/motor runs to drai n the accumul ators duri ng
the next dri ve-off.
The pump/motor i s not a servi ceabl e i tem; i f i t
requi res repl acement, the HCU must be repl aced.
ABS FUSES
The ABS fuse and the ABS pump/motor fuse are
l ocated i n the power di stri buti on center (PDC). Refer
to the sti cker on the i nsi de of the PDC cover for the
l ocati on of these fuses. The PDC i s l ocated on the
dri ver’s si de of the engi ne compartment between the
back of the battery and the brake master cyl i nder.
The CAB fuse can be found i n the fuse juncti on
bl ock under the i nstrument panel .
5 - 68 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
AMBER ABS WARNING LAMP
The amber ABS warni ng l amp i s l ocated i n the
i nstrument cl uster. The purpose of the warni ng l amp
i s di scussed i n detai l bel ow.
When the i gni ti on key i s turned to the ON posi -
ti on, the amber ABS warni ng l amp i s l i t unti l the
CAB compl etes i ts sel f-tests and turns off the l amp
(approxi matel y 4 seconds). The amber ABS warni ng
l amp wi l l i l l umi nate when the CAB detects a condi -
ti on that resul ts i n the shutdown of ABS functi on.
The CAB sends a message to the mechani cal i nstu-
ment cl uster (MI C) i nstructi ng i t to turn on the
amber ABS warni ng l amp.
Under most condi ti ons, when the amber ABS warn-
i ng l amp i s on, onl y the ABS functi on of the brake
system i s affected; The el ectroni c brake di stri buti on
(EBD), the base brake system and the abi l i ty to stop
the vehi cl e are not affected.
WHEEL SPEED SENSOR (WSS)
At each wheel of the vehi cl e there i s one wheel
speed sensor (WSS) and one tone wheel (Fi g. 3) (Fi g.
4) (Fi g. 5) (Fi g. 6). Each front wheel speed sensor i s
attached to a boss i n the steeri ng knuckl e. The front
tone wheel i s part of the dri veshaft outboard con-
stant vel oci ty joi nt. The rear wheel speed sensor i s
mounted to the rear di sc brake adapter. The rear
tone wheel i s an i ntegral part of the rear wheel hub
and beari ng.
The wheel speed sensor operates on el ectroni c
energy suppl i ed by the CAB and outputs a square
wave si gnal whose current al ternates between two
constant l evel s. I ts frequency i s proporti onal to the
speed of the tone wheel . The output i s avai l abl e as
l ong as the sensor i s powered and i ts state (hi gh or
l ow) corresponds to the presence or absence of tone
wheel teeth. The output si gnal i s sent to the CAB. I f
a wheel l ocki ng tendency i s detected by the CAB, i t
wi l l then modul ate hydraul i c pressure vi a the HCU
to prevent the wheel (s) from l ocki ng.
Correct ABS operati on i s dependent on accurate
wheel speed si gnal s. The vehi cl e’s ti res and wheel s
al l must be the same si ze and type to generate accu-
rate si gnal s. Vari ati ons i n ti re and wheel si ze can
produce i naccurate wheel speed si gnal s.
I mproper speed sensor-to-tone wheel cl earance can
cause errati c speed sensor si gnal s. The speed sensor
ai r gap i s not adjustabl e, but shoul d be checked when
appl i cabl e. Wheel speed sensor-to-tone wheel cl ear-
ance speci fi cati ons can be found i n the SPECI FI CA-
TI ONS secti on wi thi n thi s secti on i n thi s servi ce
manual group.
ELECTRONIC BRAKE DISTRIBUTION
Vehi cl es equi pped wi th ABS use el ectroni c brake
di stri buti on (EBD) to bal ance front-to-rear braki ng.
The EBD i s used i n pl ace of a rear proporti oni ng
val ve. The EBD system uses the ABS system to con-
trol the sl i p of the rear wheel s i n parti al braki ng
range. The braki ng force of the rear wheel s i s con-
trol l ed el ectroni cal l y by usi ng the i nl et and outl et
val ves l ocated i n the i ntegrated control uni t.
Upon entry i nto EBD the i nl et val ve for the rear
brake ci rcui t i s swi tched on so that the fl ui d suppl y
from the master cyl i nder i s shut off. I n order to
decrease the rear brake pressure, the outl et val ve for
Fig. 3 Left Front Wheel Speed Sensor
1 – LEFT FRONT WHEEL SPEED SENSOR
2 – TONE WHEEL
Fig. 4 Right Front Wheel Speed Sensor
1 – RIGHT FRONT WHEEL SPEED SENSOR
2 – TONE WHEEL
PL BRAKES 5 - 69
DESCRIPTION AND OPERATION (Continued)
the rear brake ci rcui t i s pul sed. Thi s al l ows fl ui d to
enter the l ow pressure accumul ator (LPA) i n the
hydraul i c control uni t (HCU) resul ti ng i n a drop i n
fl ui d pressure to the rear brakes. I n order to i ncrease
the rear brake pressure, the outl et val ve i s swi tched
off and the i nl et val ve i s pul sed. Thi s i ncreases the
pressure to the rear brakes. Thi s back-and-forth pro-
cess wi l l conti nue unti l the requi red sl i p di fference i s
obtai ned. At the end of EBD braki ng (brakes
rel eased) the fl ui d i n the LPA drai ns back to the
master cyl i nder by swi tchi ng on the outl et val ve and
drai ni ng through the i nl et val ve check val ve. At the
same ti me the i nl et val ve i s swi tched on i n case of
another brake appl i cati on.
The EBD wi l l remai n functi onal duri ng many ABS
faul t modes. I f both the red BRAKE, and amber ABS
warni ng l amps are i l l umi nated, the EBD may not be
functi oni ng.
TRACTION CONTROL SYSTEM
Tracti on control reduces wheel sl i p and mai ntai ns
tracti on at the dri vi ng wheel s at speeds bel ow 56 kph
(35 mph) when road surfaces are sl i ppery. The trac-
ti on control system reduces wheel sl i p by braki ng the
wheel that i s l osi ng tracti on.
The CAB moni tors wheel speed. Duri ng accel era-
ti on, i f the CAB detects front (dri ve) wheel sl i p and
the brakes are not appl i ed, the CAB enters tracti on
control mode. Tracti on control operati on proceeds i n
the fol l owi ng order:
(1) Cl ose the normal l y open tracti on control (TC)
val ves.
(2) Start the pump/motor and suppl y vol ume and
pressure to the front (dri ve) hydraul i c ci rcui t. (The
pump/motor runs conti nuousl y duri ng tracti on con-
trol operati on.)
(3) Open and cl ose the bui l d and decay sol enoi d
val ves to mai ntai n mi ni mum wheel sl i p and maxi -
mum tracti on.
The cycl i ng of the bui l d and decay val ves duri ng
tracti on control i s si mi l ar to that duri ng anti l ock
braki ng, except the val ves work to control wheel spi n
by appl yi ng the brakes, whereas the ABS functi on i s
to control wheel ski d by rel easi ng the brakes.
HYDRAULIC SHUTTLE VALVES
Two pressure rel i ef shuttl e val ves al l ow pressure
and vol ume to return to the master cyl i nder reservoi r
when not consumed by the bui l d and decay val ves.
These val ves are necessary because the pump/motor
suppl i es more vol ume than the system requi res.
I f the brakes are appl i ed at anyti me duri ng a trac-
ti on control cycl e, the brake l amp swi tch tri ggers the
control modul e to swi tch off tracti on control .
TRACTION CONTROL FUNCTION LAMP
The tracti on control functi on l amp i l l umi nates dur-
i ng a tracti on control cycl e, di spl ayi ng TRAC on the
i nstrument panel .
The tracti on control system i s enabl ed at each i gni -
ti on cycl e. I t may be turned off by depressi ng the
tracti on control swi tch button. The tracti on control
functi on l amp (TRAC OFF) i l l umi nates i mmedi atel y
upon depressi ng the button. Pressi ng thi s button
agai n, or turni ng off and restarti ng the vehi cl e wi l l
enabl e the tracti on control system.
Fig. 5 Left Rear Wheel Speed Sensor
1 – LEFT REAR WHEEL SPEED SENSOR
2 – TENSION STRUT
Fig. 6 Right Rear Wheel Speed Sensor
1 – RIGHT REAR WHEEL SPEED SENSOR
2 – TENSION STRUT
5 - 70 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
I f the CAB cal cul ates that the brake temperatures
are hi gh, the tracti on control system becomes i noper-
ati ve unti l a ti me-out peri od has el apsed. Duri ng thi s
“thermo-protecti on mode,” the tracti on control func-
ti on l amp i l l umi nates TRAC OFF; note that no trou-
bl e code i s regi stered.
HYDRAULIC CIRCUITS AND VALVE OPERATION
The hydraul i c shuttl e val ves control the fl ow of
pressuri zed brake fl ui d to the wheel brakes duri ng
the di fferent modes of ABS braki ng. The fol l owi ng
paragraphs expl ai n how thi s works. For purposes of
expl anati on onl y, i t i s assumed that onl y the ri ght
front wheel i s experi enci ng anti l ock braki ng; the fol -
l owi ng di agrams show onl y the ri ght front wheel i n
an anti l ock braki ng operati on.
NORMAL BRAKING HYDRAULIC CIRCUIT,
SOLENOID VALVE, AND SHUTTLE VALVE
FUNCTION (ABS WITH TRACTION CONTROL)
The hydraul i c di agram (Fi g. 7) shows a vehi cl e
wi th tracti on control i n the normal braki ng mode.
The di agram shows no wheel spi n or sl i p occurri ng
rel ati ve to the speed of the vehi cl e. The dri ver i s
appl yi ng the brake pedal ; thi s bui l ds pressure i n the
brake hydraul i c system to engage the brakes and
stop the vehi cl e. The hydraul i c shuttl e val ve cl oses
wi th every brake pedal appl i cati on so pressure i s not
created at the i nl et to the pump/motor.
Fig. 7 ABS With Traction Control - Normal Braking Hydraulic Circuit
1 – OUTLET VALVE
2 – PUMP PISTON
3 – PUMP MOTOR (OFF)
4 – SUCTION VALVE
5 – LOW PRESSURE ACCUMULATOR
6 – NORMALLY CLOSED VALVE (OFF)
7 – TO RIGHT FRONT WHEEL
8 – NORMALLY OPEN VALVE (OFF)
9 – NORMALLY OPEN ASR VALVE (OFF)
10 – FROM MASTER CYLINDER
11 – HYDRAULIC SHUTTLE VALVE
12 – MASTER CYLINDER PRESSURE
13 – NOISE DAMPER CHAMBER
PL BRAKES 5 - 71
DESCRIPTION AND OPERATION (Continued)
ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID
VALVE, AND SHUTTLE VALVE FUNCTION (ABS
WITH TRACTION CONTROL)
The hydraul i c di agram (Fi g. 8) shows the vehi cl e i n
the ABS braki ng mode. The di agram shows one
wheel i s sl i ppi ng because the dri ver i s attempti ng to
stop the vehi cl e at a faster rate than i s al l owed by
the surface on whi ch the ti res are ri di ng.
• The hydraul i c shuttl e val ve cl oses upon brake
appl i cati on so that the pump/motor cannot si phon
brake fl ui d from the master cyl i nder.
• The normal l y open and normal l y cl osed val ves
modul ate (bui l d/decay) the brake hydraul i c pressure
as requi red.
• The pump/motor i s swi tched on so that the
brake fl ui d from the l ow pressure accumul ators i s
returned to the master cyl i nder ci rcui ts.
• The brake fl ui d i s routed to ei ther the master
cyl i nder or the wheel brake dependi ng on the posi -
ti on of the normal l y open val ve.
Fig. 8 ABS With Traction Control - ABS Braking Hydraulic Circuit
1 – OUTLET VALVE
2 – PUMP PISTON
3 – PUMP MOTOR (ON)
4 – SUCTION VALVE
5 – LOW PRESSURE ACCUMULATOR
6 – NORMALLY CLOSED VALVE (MODULATING)
7 – TO RIGHT FRONT WHEEL
8 – NORMALLY OPEN VALVE (MODULATING)
9 – NORMALLY OPEN ASR VALVE (OFF)
10 – FROM MASTER CYLINDER
11 – HYDRAULIC SHUTTLE VALVE
12 – MASTER CYLINDER PRESSURE
13 – CONTROLLED WHEEL PRESSURE
14 – LOW PRESSURE ACCUMULATOR PRESSURE
15 – PUMP INTERSTAGE PRESSURE
16 – NOISE DAMPER CHAMBER
5 - 72 BRAKES PL
DESCRIPTION AND OPERATION (Continued)
ABS TRACTION CONTROL HYDRAULIC CIRCUIT,
SOLENOID VALVE, AND SHUTTLE VALVE
FUNCTION (ABS WITH TRACTION CONTROL)
The hydraul i c di agram (Fi g. 9) shows the vehi cl e i n
the tracti on control (TC) mode. The di agram shows a
dri ve wheel i s spi nni ng and brake pressure i s
requi red to reduce i ts speed.
• The normal l y open TC (ASR) val ve i s energi zed
to i sol ate the brake fl ui d bei ng pumped from the
master cyl i nder and to i sol ate the dri ven wheel .
• The normal l y open TC (ASR) val ve bypasses the
pump output back to the master cyl i nder at a fi xed
pressure setti ng.
• The normal l y open and normal l y cl osed val ves
modul ate (bui l d/decay) the brake pressure as
requi red to the spi nni ng wheel .
Fig. 9 Traction Control Hydraulic Circuit
1 – OUTLET VALVE
2 – PUMP PISTON
3 – PUMP MOTOR (ON)
4 – LOW PRESSURE ACCUMULATOR PRESSURE
5 – LOW PRESSURE ACCUMULATOR
6 – NORMALLY CLOSED VALVE (MODULATING)
7 – TO RIGHT FRONT WHEEL (SPINNING)
8 – NORMALLY OPEN VALVE (MODULATING)
9 – NORMALLY OPEN ASR VALVE ON (REGULATING)
10 – FROM MASTER CYLINDER
11 – HYDRAULIC SHUTTLE VALVE
12 – CONTROLLED WHEEL PRESSURE
13 – SUCTION VALVE
14 – PUMP INTERSTAGE PRESSURE
15 – NOISE DAMPER CHAMBER
16 – MASTER CYLINDER PRESSURE
17 – PUMP PRESSURE
PL BRAKES 5 - 73
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
SERVICE WARNINGS AND CAUTIONS
The ABS uses an el ectroni c control modul e, the
CAB. Thi s modul e i s desi gned to wi thstand normal
current draws associ ated wi th vehi cl e operati on.
Care must be taken to avoi d overl oadi ng the CAB
ci rcui ts.
CAUTION: In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so for a diagnostic proce-
dure.
CAUTION: These circuits should only be tested
using a high impedance multi-meter or the DRB
scan tool as described in this section. Power
should never be removed or applied to any control
module with the ignition in the ON position. Before
removing or connecting battery cables, fuses, or
connectors, always turn the ignition to the OFF
position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, etc.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
ABS GENERAL DIAGNOSTICS INFORMATION
Thi s secti on contai ns i nformati on necessary to
di agnose the anti l ock brake system. Speci fi cal l y, thi s
secti on shoul d be used to hel p di agnose condi ti ons
whi ch resul t i n any of the fol l owi ng:
(1) amber ABS warni ng l amp turned on.
(2) brakes l ock-up on hard appl i cati on.
Di agnosi s of base brake condi ti ons that are obvi -
ousl y mechani cal i n nature shoul d be di rected to
BASE BRAKE SYSTEM at the begi nni ng of thi s
group.
Many ABS condi ti ons judged to be a probl em by
the dri ver may be normal operati ng condi ti ons. See
ABS OPERATI ON i n the DESCRI PTI ON AND
OPERATI ON secti on of thi s group to become fami l -
i ari zed wi th the normal characteri sti cs of thi s
anti l ock brake system.
ABS WIRING DIAGRAM INFORMATION
Duri ng the di agnosi s and testi ng of the anti l ock
brake system i t may become necessary to reference
the wi ri ng di agrams coveri ng the anti l ock brake sys-
tem and i ts components. For wi ri ng di agrams refer to
GROUP 8W of thi s servi ce manual . I t wi l l provi de
you wi th the wi ri ng di agrams and the ci rcui t descri p-
ti on and operati on i nformati on coveri ng the anti l ock
brake system.
ABS VEHICLE TEST DRIVE
Most ABS compl ai nts wi l l requi re a test dri ve to
properl y dupl i cate and di agnose the condi ti on.
WARNING: CONDITIONS THAT RESULT IN TURN-
ING ON THE RED BRAKE WARNING LAMP MAY
INDICATE REDUCED BRAKING ABILITY.
Before test dri vi ng a brake compl ai nt vehi cl e, note
whether the red BRAKE warni ng l amp, amber ABS
warni ng l amp, or both are turned on. I f i t i s the red
BRAKE warni ng l amp, there i s a brake hydraul i c
probl em that must be corrected before dri vi ng the
vehi cl e. Refer to the BASE BRAKE SYSTEM for
di agnosi s of the red BRAKE warni ng l amp. I f the red
brake warni ng l amp i s i l l umi nated, there i s al so a
possi bi l i ty that there i s an ABS probl em and the
amber ABS warni ng l amp i s not abl e to i l l umi nate,
so the MI C turns on the red Brake warni ng l amp by
defaul t.
I f the amber ABS warni ng l amp i s on, test dri ve
the vehi cl e as descri bed bel ow. Whi l e the amber ABS
warni ng l amp i s on, the ABS i s not functi onal . The
abi l i ty to stop the car usi ng the base brake system
shoul d not be affected.
I f a functi onal probl em of the ABS i s determi ned
whi l e test dri vi ng the vehi cl e, refer to the Chassi s
Di agnosti c Procedures manual .
(1) Turn the key to the OFF posi ti on and then
back to the ON posi ti on. Note whether the amber
ABS warni ng l amp conti nues to stay on. I f i t does,
refer to the di agnosti c manual .
(2) I f the amber ABS warni ng l amp goes out, shi ft
i nto gear and dri ve the car to a speed of 20 kph (12
mph) to compl ete the ABS start-up and dri ve-off
cycl es (see ABS ELECTRONI C DI AGNOSI S). I f at
thi s ti me the amber ABS warni ng l amp comes on,
refer to the di agnosti c manual .
(3) I f the amber ABS warni ng l amp remai ns out,
dri ve the vehi cl e a short di stance. Accel erate the
vehi cl e to a speed of at l east 40 mph. Bri ng the vehi -
cl e to a compl ete stop, braki ng hard enough to cause
the ABS to cycl e. Agai n accel erate the vehi cl e past 25
mph. Refer to the di agnosti c manual for further test-
i ng of the anti l ock brake system.
5 - 74 BRAKES PL
ABS ELECTRONIC DIAGNOSIS
The fol l owi ng i nformati on i s presented to gi ve the
techni ci an a general background on the di agnosti c
capabi l i ti es of the ABS system. Compl ete el ectroni c
di agnosi s of the ABS system used on thi s vehi cl e i s
covered i n the Chassi s Di agnosti c Procedures manual .
El ectroni c di agnosi s of the ABS system used on
thi s vehi cl e i s performed usi ng the DRBI I I ௡ scan
tool . The vehi cl e’s scan tool di agnosti c connector i s
l ocated under the steeri ng col umn l ower cover, to the
l eft si de of the steeri ng col umn (Fi g. 10).
ABS SELF-DIAGNOSIS
The ABS system i s equi pped wi th a sel f-di agnosi s
capabi l i ty, whi ch may be used to assi st i n the i sol a-
ti on of ABS faul ts. The features are descri bed bel ow.
START-UP CYCLE
The sel f-di agnosi s ABS start-up cycl e begi ns when
the i gni ti on swi tch i s turned to the ON posi ti on.
El ectri cal checks are compl eted on ABS components,
i ncl udi ng the CAB, sol enoi d conti nui ty, and the rel ay
system operati on. Duri ng thi s check the amber ABS
warni ng l amp i s turned on for approxi matel y 5 sec-
onds and the brake pedal may emi t a poppi ng sound,
movi ng sl i ghtl y when the sol enoi d val ves are
checked.
DRIVE-OFF CYCLE
The fi rst ti me the vehi cl e i s set i n moti on after an
i gni ti on off/on cycl e, the dri ve-off cycl e occurs. Thi s
cycl e i s performed when the vehi cl e reaches a speed
of approxi matel y 20 kph (12 mph.).
• The pump/motor i s bri efl y acti vated to veri fy
functi on. When the pump/motor i s bri efl y acti vated, a
whi rl i ng or buzzi ng sound may be heard by the
dri ver. Thi s sound i s normal , i ndi cati ng the pump/
motor i s runni ng.
• The wheel speed sensor output correct operati ng
range i s veri fi ed.
ONGOING TESTS
Whi l e the system i s operati ng, these tests are per-
formed on a conti nuous basi s:
• sol enoi d conti nui ty
• wheel speed sensor conti nui ty
• wheel speed sensor output
DIAGNOSTIC TROUBLE CODES (DTC’s)
Di agnosti c troubl e codes (DTC’s) are kept i n the
control l er’s memory unti l ei ther erased by the techni -
ci an usi ng the DRB, or erased automati cal l y after
3500 mi l es or 255 i gni ti on key cycl es, whi chever
occurs fi rst. DTC’s are retai ned by the control l er
even i f the i gni ti on i s turned off or the battery i s di s-
connected. More than one DTC can be stored at a
ti me. When accessed, the number of occurrences
(i gni ti on key cycl es) and the DTC that i s stored are
di spl ayed. Most functi ons of the CAB and the ABS
system can be accessed by the techni ci an for testi ng
and di agnosti c purposes usi ng the DRB.
LATCHING VERSUS NON-LATCHING DIAGNOSTIC TROUBLE
CODES
Some DTC’s detected by the CAB are “l atchi ng”
codes. The DTC i s l atched and ABS braki ng i s di s-
abl ed unti l the i gni ti on swi tch i s reset. Thus, ABS
braki ng i s non-operati onal even i f the ori gi nal DTC
has di sappeared. Other DTC’s are non-l atchi ng. Any
warni ng l amps that are turned on are onl y turned on
as l ong as the DTC condi ti on exi sts; as soon as the
condi ti on goes away, the amber ABS warni ng l amp i s
turned off, al though, i n most cases, a DTC i s set.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As wi th vi rtual l y any el ectroni c system, i ntermi t-
tent el ectri cal probl ems i n the ABS system may be
di ffi cul t to accuratel y di agnose. Most i ntermi ttent
el ectri cal probl ems are caused by faul ty el ectri cal
connecti ons or wi ri ng. A vi sual i nspecti on shoul d be
done before tryi ng to di agnose or servi ce the anti l ock
brake system; thi s wi l l el i mi nate unnecessary di ag-
nosi s and testi ng ti me. Perform a vi sual i nspecti on
for l oose, di sconnected, damaged, or mi srouted wi res
or connectors; i ncl ude the fol l owi ng components and
areas of the vehi cl e i n the i nspecti on.
(1) I nspect fuses i n the power di stri buti on center
(PDC) and the wi ri ng juncti on bl ock. Veri fy that al l
fuses are ful l y i nserted i nto the PDC and wi ri ng
Fig. 10 ABS System Diagnostic Connector Location
1 – DRIVER AIRBAG MODULE
2 – PASSENGER AIRBAG MODULE
3 – DATA LINK CONNECTOR
PL BRAKES 5 - 75
DIAGNOSIS AND TESTING (Continued)
juncti on bl ock. A l abel on the undersi de of the PDC
cover i denti fi es the l ocati ons of the ABS fuses.
(2) I nspect the 25-way el ectri cal connector at the
CAB for damaged, spread, or backed-out wi ri ng ter-
mi nal s. Veri fy that the 25-way connector i s ful l y
i nserted i n the socket of the CAB. Be sure that wi res
are not stretched ti ght or pul l ed out of the connector.
(3) Veri fy that al l the wheel speed sensor connec-
ti ons are secure.
(4) Look for poor mati ng of connector hal ves or ter-
mi nal s not ful l y seated i n the connector body.
(5) Check for i mproperl y formed or damaged termi -
nal s. Al l connector termi nal s i n a suspect ci rcui t shoul d
be careful l y reformed to i ncrease contact tensi on.
(6) Look for poor termi nal -to-wi re connecti ons.
Thi s requi res removi ng the termi nal from the connec-
tor body to i nspect i t.
(7) Veri fy pi n presence i n the connector assembl y
(8) Check for proper ground connecti ons. Check al l
ground connecti ons for si gns of corrosi on, l oose fas-
teners, or other potenti al defects. Refer to the wi ri ng
di agrams for ground l ocati ons.
(9) Look for probl ems wi th the mai n power sources
of the vehi cl e. I nspect the battery, generator, i gni ti on
ci rcui ts and other rel ated rel ays and fuses.
I f a vi sual check does not fi nd the cause of the
probl em, operate the car i n an attempt to dupl i cate
the condi ti on and record any troubl e codes.
Most fai l ures of the ABS di sabl e the ABS functi on
for the enti re i gni ti on cycl e even i f the faul t cl ears
before key-off. There are some fai l ure condi ti ons,
however, that al l ow ABS operati on to resume duri ng
the i gni ti on cycl e i n whi ch the troubl e occurred even
i f the troubl e condi ti ons are no l onger present.
The fol l owi ng troubl e condi ti ons may resul t i n
i ntermi ttent i l l umi nati on of the amber ABS warni ng
l amp.
• Low system vol tage. I f Low System Vol tage i s
detected by the CAB, the CAB wi l l turn on the ABS
Warni ng Lamp unti l normal system vol tage i s
achi eved. Once normal vol tage i s seen at the CAB,
normal operati on resumes.
• Hi gh system vol tage. I f hi gh system vol tage i s
detected by the CAB, the CAB wi l l turn on the
Amber ABS Warni ng Lamp unti l normal system vol t-
age i s achi eved. Once normal vol tage i s agai n
detected by the CAB, normal ABS operati on resumes.
Addi ti onal possi bl e causes that may resul t i n the
i l l umi nati on of the amber ABS warni ng l amp are as
fol l ows:
• Any condi ti on that i nterrupts el ectri cal current
to the CAB may cause the amber ABS warni ng l amp
to turn on i ntermi ttentl y.
• I f PCI communi cati on between the body control -
l er and the CAB i s i nterrupted, the body control l er
can turn on the amber ABS warni ng l amp.
TONE WHEEL
Tone wheel s can cause errati c wheel speed sensor
si gnal s. I nspect tone wheel s for the fol l owi ng possi bl e
causes:
• mi ssi ng, chi pped, or broken teeth
• contact wi th the wheel speed sensor
• wheel speed sensor to tone wheel al i gnment
• wheel speed sensor to tone wheel cl earance
• excessi ve tone wheel runout
• tone wheel l oose on i ts mounti ng surface
I f a front tone wheel i s found to need repl acement,
the dri ve shaft must be repl aced. No attempt shoul d
be made to repl ace just the tone wheel . Refer to the
DI FFERENTI AL AND DRI VELI NE group i n thi s
servi ce manual for removal and i nstal l ati on.
I f a rear tone wheel i s found to need repl acement,
the rear hub and beari ng must be repl aced. No
attempt shoul d be made to repl ace just the tone
wheel . Refer to the SUSPENSI ON group i n thi s ser-
vi ce manual for removal and i nstal l ati on.
I f wheel speed sensor to tone wheel contact i s evi -
dent, determi ne the cause and correct i t before
repl aci ng the wheel speed sensor or tone wheel .
Check the gap between the speed sensor head and
the tone wheel to ensure i t i s wi thi n speci fi cati ons.
Refer to SPECI FI CATI ONS i n thi s secti on of the ser-
vi ce manual for the mi ni mum and maxi mum wheel
speed sensor to tone wheel cl earance.
Excessi ve wheel speed sensor runout can cause
errati c wheel speed sensor si gnal s. Refer to SPECI -
FI CATI ONS i n thi s secti on of the servi ce manual for
the maxi mum al l owed tone wheel runout. I f tone
wheel runout i s excessi ve, determi ne i f i t i s caused
by a defect i n the dri veshaft assembl y or hub and
beari ng. Repl ace as necessary.
Tone wheel s are pressed onto thei r mounti ng sur-
faces and shoul d not rotate i ndependentl y from the
mounti ng surface. Repl acement of the front dri ve-
shaft or rear hub and beari ng i s necessary.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts. Swel l i ng i ndi cates the
presence of petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f the fl ui d sep-
arates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f the brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush the brake system. Repl ace al l the rubber
parts or components contai ni ng rubber comi ng i nto
contact wi th the brake fl ui d i ncl udi ng: the master
cyl i nder; proporti oni ng val ves; cal i per seal s; wheel
cyl i nder seal s; ABS hydraul i c control uni t; and al l
hydraul i c fl ui d hoses.
5 - 76 BRAKES PL
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
BRAKE FLUID LEVEL CHECKING
CAUTION: Use only Mopar brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
Refer to SERVI CE PROCEDURES i n the BASE
BRAKE SYSTEM secti on i n thi s group for the proper
procedure to check and adjust the brake fl ui d l evel i n
the master cyl i nder fl ui d reservoi r.
ANTILOCK BRAKE SYSTEM BLEEDING
The base brake’s hydraul i c system must be bl ed
anyti me ai r enters the hydraul i c system. The ABS
though, parti cul arl y the I CU (HCU), shoul d onl y be
bl ed when the HCU i s repl aced or removed from the
vehi cl e. The ABS must al ways be bl ed anyti me i t i s
suspected that the HCU has i ngested ai r. Under
most ci rcumstances that requi re the bl eedi ng of the
brakes hydraul i c system, onl y the base brake
hydraul i c system needs to be bl ed.
I t i s i mportant to note that excessi ve ai r i n the
brake system wi l l cause a soft or spongy feel i ng
brake pedal .
Duri ng the brake bl eedi ng procedure, be sure the
brake fl ui d l evel remai ns cl ose to the FULL l evel i n
the master cyl i nder fl ui d reservoi r. Check the fl ui d
l evel peri odi cal l y duri ng the bl eedi ng procedure and
add DOT 3 brake fl ui d as requi red.
The ABS must be bl ed as two i ndependent braki ng
systems. The non-ABS porti on of the brake system
wi th ABS i s to be bl ed the same as any non-ABS sys-
tem.
The ABS porti on of the brake system must be bl ed
separatel y. Use the fol l owi ng procedure to properl y
bl eed the brake hydraul i c system i ncl udi ng the ABS.
BLEEDING
When bl eedi ng the ABS system, the fol l owi ng
bl eedi ng sequence must be fol l owed to i nsure com-
pl ete and adequate bl eedi ng.
(1) Make sure al l hydraul i c fl ui d l i nes are i nstal l ed
and properl y torqued.
(2) Connect the DRB scan tool to the di agnosti cs
connector. The di agnosti c connector i s l ocated under
the l ower steeri ng col umn cover to the l eft of the
steeri ng col umn.
(3) Usi ng the DRB, check to make sure the CAB
does not have any faul t codes stored. I f i t does, cl ear
them usi ng the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM
WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS
AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT
THE FLOW OF BRAKE FLUID AWAY FROM YOUR-
SELF AND THE PAINTED SURFACES OF THE VEHI-
CLE. BRAKE FLUID AT HIGH PRESSURE MAY
COME OUT OF THE BLEEDER SCREWS WHEN
OPENED.
(4) Bl eed the base brake system usi ng the stan-
dard pressure or manual bl eedi ng procedure as out-
l i ned i n SERVI CE PROCEDURES i n the BASE
BRAKE SYSTEM secti on at the begi nni ng of thi s
group.
(5) Usi ng the DRB, sel ect ANTI LOCK BRAKES,
fol l owed by MI SCELLANEOUS, then BLEED
BRAKES. Fol l ow the i nstructi ons di spl ayed. When
the scan tool di spl ays TEST COMPLETED, di scon-
nect the scan tool and proceed.
(6) Bl eed the base brake system a second ti me.
Check brake fl ui d l evel i n the reservoi r peri odi cal l y
to prevent emptyi ng, causi ng ai r to enter the hydrau-
l i c system.
(7) Fi l l the master cyl i nder reservoi r to the ful l
l evel .
(8) Test dri ve the vehi cl e to be sure the brakes are
operati ng correctl y and that the brake pedal does not
feel spongy.
MASTER CYLINDER BLEEDING
(1) Cl amp the master cyl i nder i n a vi se.
(2) Attach Master Cyl i nder Bl eed Tube, Speci al
Tool 8358-1, to the pri mary port of the master cyl i n-
der and ti ghten i n pl ace (Fi g. 11). Attach Master Cyl -
i nder Bl eed Tube, Speci al Tool 8358-2, to the
secondary port of the master cyl i nder and ti ghten i n
pl ace. Posi ti on the other end of the tubes i nto the
master cyl i nder reservoi r so thei r outl ets are bel ow
the surface of the brake fl ui d i n the reservoi r when
fi l l ed.
(3) Fi l l the brake fl ui d reservoi r wi th Mopar௡
brake fl ui d, or an equi val ent conformi ng to DOT 3
speci fi cati ons.
(4) Usi ng a wooden dowel as a pushrod (Fi g. 11),
press the pi stons i nward sl owl y appl yi ng brake pres-
sure, then rel ease the pressure, al l owi ng the pi stons
to return to the rel eased posi ti on. Repeat thi s several
ti mes unti l al l ai r bubbl es are expel l ed out of the
tubes and master cyl i nder bore.
(5) Remove the bl eed tubes from the master cyl i n-
der and pl ug the outl et ports.
(6) I nstal l the fi l l cap on the reservoi r.
(7) Remove the master cyl i nder from the vi se.
PL BRAKES 5 - 77
NOTE: It is not necessary to bleed the entire
hydraulic system after replacing just the master cyl-
inder unless the brake system has been open to air
for an excessive amount of time or air is present in
the lines. Only the master cylinder must be bled
and filled.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
Revi ew thi s enti re secti on pri or to performi ng any
mechani cal work on a vehi cl e equi pped wi th ABS.
Thi s secti on contai ns i nformati on on precauti ons per-
tai ni ng to potenti al component damage, vehi cl e dam-
age and personal i njury whi ch coul d resul t when
servi ci ng an ABS equi pped vehi cl e.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: An attempt to remove or disconnect cer-
tain system components may result in improper
system operation. Only those components with
approved removal and installation procedures in
this manual should be serviced.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash off with water immediately.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS do not apply a
12-volt power source to the ground circuit of the
pump motor in the HCU. Doing this will damage the
pump motor and will require replacement of the
entire HCU.
CAUTION: If welding work is to be performed on
the vehicle, using an electric arc welder, the CAB
connector should be disconnected during the weld-
ing operation.
CAUTION: The CAB 25-way connector should never
be connected or disconnected with the ignition
switch in the ON position.
Many components of the ABS System are not ser-
vi ceabl e and must be repl aced as an assembl y. Do not
di sassembl e any component whi ch i s not desi gned to
be servi ced.
MASTER CYLINDER
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) Wi th the engi ne not runni ng, pump the brake
pedal 4-5 strokes unti l the pedal feel i s fi rm.
(2) Di sconnect the negati ve (ground) cabl e from
the battery and i sol ate the cabl e.
(3) Di sconnect the posi ti ve cabl e from the battery,
then remove the battery from the battery tray. There
i s one nut securi ng the cl amp on the backsi de of the
battery hol di ng i t i n pl ace.
(4) Di sconnect the wi ri ng harness connector from
the brake fl ui d l evel swi tch on the master cyl i nder
reservoi r (Fi g. 12).
Fig. 11 Bleeding Master Cylinder
1 – WOODEN DOWEL
2 – MASTER CYLINDER
5 - 78 BRAKES PL
SERVICE PROCEDURES (Continued)
(5) Di sconnect the pri mary and secondary brake
tubes from master cyl i nder (Fi g. 12). I nstal l pl ugs i n
the master cyl i nder outl et ports.
(6) Cl ean the area around where the master cyl i n-
der attaches to the power brake booster usi ng a sui t-
abl e brake cl eaner such as Mopar௡ Brake Parts
Cl eaner or an equi val ent.
(7) Remove the 2 nuts attachi ng master cyl i nder to
power brake booster (Fi g. 12).
(8) Sl i de the master cyl i nder strai ght out of the
power brake booster.
INSTALLATION
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) Bl eed the master cyl i nder before i nstal l i ng i t
on the vehi cl e. Refer to MASTER CYLI NDER
BLEEDI NG i n SERVI CE PROCEDURES wi thi n thi s
secti on of thi s servi ce manual group.
(2) Wi pe the face of the power brake booster cl ean
where the master cyl i nder seal comes i n contact
when i t’s i nstal l ed. Do not get any cl eaner or debri s
i nsi de the booster.
(3) Posi ti on the master cyl i nder on the studs of
power brake vacuum booster al i gni ng the booster
push rod wi th the master cyl i nder push rod. Care-
ful l y push the master cyl i nder onto the studs unti l i t
contacts the face of the booster.
(4) I nstal l the two master cyl i nder mounti ng nuts
(Fi g. 12). Ti ghten the mounti ng nuts to a torque of
28 N·m (250 i n. l bs.).
(5) Connect the pri mary and secondary brake
tubes to the master cyl i nder pri mary and secondary
ports (Fi g. 12). Ti ghten the nuts to a torque of 17
N·m (145 i n. l bs.).
(6) I nstal l the wi ri ng harness connector on the
master cyl i nder reservoi r fl ui d l evel swi tch.
(7) I nstal l the battery and cl amp i n pl ace.
(8) Connect the posi ti ve, then the negati ve
(ground) cabl e on the battery.
(9) Fi l l the master cyl i nder to the proper fi l l l evel .
(10) Road test the vehi cl e to ensure proper opera-
ti on of the base and anti l ock brake systems.
INTEGRATED CONTROL UNIT
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Usi ng a brake pedal hol der, depress the brake
pedal past i ts fi rst one i nch of travel and hol d i t i n
thi s posi ti on (Fi g. 13). Thi s wi l l i sol ate the master
cyl i nder from the brake hydraul i c system and wi l l
not al l ow the brake fl ui d to drai n out of the master
cyl i nder reservoi r.
(2) Di sconnect negati ve (ground) cabl e from the
battery and i sol ate the cabl e.
(3) Di sconnect the posi ti ve cabl e from the battery,
then remove the battery from the battery tray. There
i s one nut securi ng the cl amp on the backsi de of the
battery hol di ng i t i n pl ace.
(4) Remove the one nut and one bol t securi ng the
ai r cl eaner box i n pl ace, then di sconnect the wi ri ng
harness connector at the ai r i nl et sensor.
(5) Li ft the ai r cl eaner box upward enough to cl ear
i ts grommeted al i gnment post (Fi g. 14), then move
the ai r cl eaner box forward just enough to access the
battery tray mounti ng bol ts.
(6) Remove the 2 bol ts, then the 2 nuts mounti ng
the battery tray to i ts bracket (Fi g. 14). Remove the
battery tray.
Fig. 12 Master Cylinder
1 – POWER BRAKE BOOSTER
2 – CONNECTOR
3 – BRAKE FLUID LEVEL SWITCH
4 – MOUNTING NUTS
5 – SECONDARY BRAKE TUBE
6 – PRIMARY BRAKE TUBE
PL BRAKES 5 - 79
REMOVAL AND INSTALLATION (Continued)
(7) Di sconnect the pri mary and secondary brake
tubes from the master cyl i nder (Fi g. 15). I nstal l
pl ugs i n the master cyl i nder outl et ports.
(8) Di sconnect the 25-way connector from the con-
trol l er anti l ock brake (CAB) mounted on the i nte-
grated control uni t (I CU) and move i t out of the way.
The connector i s di sconnected by pul l i ng outward on
the connector l ock (Fi g. 16). Thi s wi l l unl ock and
rai se the 25-way connector out of the socket on the
CAB.
(9) Tag the brake tubes comi ng from the master
cyl i nder as pri mary and secondary (Fi g. 15). Thi s i s
done to avoi d mi x-up once the tubes are removed
from the vehi cl e.
(10) Di sconnect and remove the pri mary and sec-
ondary brake tubes comi ng from the master cyl i nder
at the I CU hydraul i c control uni t (HCU) (Fi g. 15).
(11) Di sconnect the brake tubes goi ng to each i ndi -
vi dual brake at the HCU (Fi g. 15).
(12) Remove the 3 bol ts attachi ng the I CU to i ts
mounti ng bracket (Fi g. 17).
(13) Remove the I CU from the vehi cl e.
Fig. 13 Brake Pedal Holder
1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 – THROTTLE PEDAL
3 – BRAKE PEDAL HOLDING TOOL
4 – STEERING WHEEL
5 – DRIVER’S SEAT
6 – BRAKE PEDAL
Fig. 14 Battery Tray Mounting
1 – BATTERY TRAY MOUNTING NUTS
2 – BATTERY TRAY MOUNTING BOLTS
3 – AIR CLEANER BOX POST
Fig. 15 Brake Tube Locations
1 – PRIMARY BRAKE TUBE
2 – SECONDARY BRAKE TUBE
3 – BRAKE TUBES FROM MASTER CYLINDER
4 – BRAKE TUBES TO BRAKES
Fig. 16 Connector Lock Pulled Outward
1 – MASTER CYLINDER
2 – 25–WAY CONNECTOR
3 – CAB
4 – CONNECTOR LOCK PULLED OUTWARD
5 – ICU
5 - 80 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
(14) Refer to DI SASSEMBLY AND ASSEMBLY i n
thi s secti on of thi s group for the procedure on sepa-
rati ng and reattachi ng the CAB to the HCU.
INSTALLATION
(1) I nstal l the I CU onto i ts mounti ng bracket.
(2) I nstal l the 3 bol ts attachi ng the I CU to the
mounti ng bracket (Fi g. 17). Ti ghten the 3 mounti ng
bol ts to a torque of 11 N·m (97 i n. l bs.)
(3) I nstal l the four brake tubes goi ng to the brakes
i nto thei r respecti ve outl et ports on the I CU HCU
(Fi g. 15). Usi ng a crow foot on a torque wrench,
ti ghten the four brake tube nuts to a torque of 17
N·m (145 i n. l bs.).
NOTE: When installing the brake tubes from the
master cylinder on the HCU, the brake tube with the
small tube nut is to be installed in the forward-most
port on the HCU with the small end going toward
the master cylinder secondary port.
(4) I nstal l the pri mary and secondary brake tubes
from the master cyl i nder onto the HCU (Fi g. 15). Do
not compl etel y ti ghten the pri mary and secondary
tubes at thi s ti me.
(5) Connect the pri mary and secondary brake
tubes to the master cyl i nder ports (Fi g. 15).
(6) Usi ng a crow foot on a torque wrench, ti ghten
the pri mary and secondary brake tube nuts at both
the master cyl i nder and HCU to a torque of 17 N·m
(145 i n. l bs.).
CAUTION: Before installing the 25-way connector
in the CAB, be sure the seal is properly installed in
the connector.
(7) I nstal l the 25-way connector i nto the socket of
the CAB as fol l ows:
• Posi ti on the 25-way connector i n the socket of
the CAB and careful l y push i t down as far as possi -
bl e (Fi g. 16).
• When the connector i s ful l y seated i nto the CAB
socket, push the connector l ock i nward. Thi s pul l s
the connector i nto the socket of the CAB and l ocks i t
i n the i nstal l ed posi ti on.
(8) Posi ti on the battery tray back i n pl ace. I nstal l
the two bol ts, then the two nuts mounti ng the bat-
tery tray to i ts bracket (Fi g. 14). Ti ghten the two
bol ts and nuts to a torque of 15 N·m (135 i n. l bs.).
(9) Rei nstal l the ai r cl eaner box onto i ts grom-
meted al i gnment post (Fi g. 14).
(10) I nstal l the one nut and one bol t securi ng the
ai r cl eaner box i n pl ace, then connect the wi ri ng har-
ness connector at the ai r i nl et sensor.
(11) I nstal l the battery and cl amp i t i n pl ace.
Ti ghten the hol d-down cl amp bol t to a torque of 12
N·m (105 i n. l bs.).
(12) Connect the posi ti ve, then the negati ve
(ground) cabl e on the battery.
(13) Bl eed the base and the ABS hydraul i c sys-
tems. Refer to ANTI LOCK BRAKE SYSTEM
BLEEDI NG i n thi s secti on of thi s servi ce manual
group.
(14) Fi l l the master cyl i nder to the proper fi l l
l evel .
(15) Road test the vehi cl e to ensure proper opera-
ti on of the base and anti l ock brake systems.
WHEEL SPEED SENSOR (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Di sconnect the wheel speed sensor cabl e con-
nector from the wi ri ng harness on the i nsi de of the
frame rai l above the front suspensi on crossmember
(Fi g. 18). The connector has a l ocki ng tab whi ch that
must be pul l ed back before the connector rel ease
tang can be depressed, rel easi ng the connecti on.
(3) Remove the speed sensor cabl e grommet from
the retai ni ng bracket attached to the brake hose on
the outsi de of the frame rai l .
(4) Remove the bol t mounti ng the wheel speed sen-
sor head to the steeri ng knuckl e (Fi g. 19).
Fig. 17 ICU Mounting Bolts
1 – ICU
2 – ICU MOUNTING BOLTS
PL BRAKES 5 - 81
REMOVAL AND INSTALLATION (Continued)
CAUTION: When removing a wheel speed sensor
from the knuckle, do not use pliers on the sensor
head. This may damage the sensor head. If the sen-
sor has seized, use a hammer and a punch to tap
the edge of the sensor head ear, rocking the sensor
side-to-side until free.
(5) Careful l y, remove the sensor head from the
steeri ng knuckl e.
(6) Remove the screw securi ng the wheel speed
sensor to the rear of the strut (Fi g. 20). Remove the
wheel speed sensor.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Attach the wheel speed sensor to the strut
usi ng the i ts mounti ng screw (Fi g. 20).
(2) I nstal l the wheel speed sensor head i n the
steeri ng knuckl e (Fi g. 19). I nstal l the mounti ng bol t.
Ti ghten the mounti ng bol t to a torque of 12 N·m (105
i n. l bs.).
(3) From the sensor bracket on the strut, l oop the
sensor cabl e upward, then downward at the outsi de
of the frame rai l . I nstal l the speed sensor cabl e grom-
met onto the retai ni ng bracket attached to the brake
hose on the outsi de of the frame rai l .
(4) Loop the wheel speed sensor cabl e around the
bottom of the frame rai l and connect i t to the wi ri ng
harness connector on the i nsi de of the frame rai l
(Fi g. 18). Remember to push i n the l ocki ng tab on the
connector.
(5) I nstal l the ti re and wheel assembl y.
(6) Lower the vehi cl e.
(7) Road test vehi cl e to ensure proper operati on of
the base brakes and ABS.
Fig. 18 Wiring Harness Connector
1 – RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 – RIGHT FRONT DRIVESHAFT
3 – ENGINE OIL FILTER
Fig. 19 Wheel Speed Sensor
1 – RIGHT FRONT WHEEL SPEED SENSOR
2 – TONE WHEEL
Fig. 20 Wheel Speed Sensor At Strut
1 – ABS WHEEL SPEED SENSOR ROUTING BRACKET (IF
EQUIPPED)
2 – GROUND STRAP
3 – GROUND STRAP SCREW
4 – ABS SENSOR BRACKET SCREW (IF EQUIPPED)
5 - 82 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
WHEEL SPEED SENSOR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Rai se the vehi cl e. Refer to HOI STI NG i n the
LUBRI CATI ON AND MAI NTENANCE group for the
proper l i fti ng procedure.
(2) Remove the ti re and wheel assembl y from the
vehi cl e.
(3) Di sconnect the wheel speed sensor cabl e con-
nector from the vehi cl e wi ri ng harness (Fi g. 21).
Remove the cl i p attachi ng wheel speed sensor cabl e
connector to the vehi cl e’s body.
(4) Remove the wheel speed sensor cabl e routi ng
bracket from under rear brake fl ex hose mounti ng
bracket. Then remove the speed sensor cabl e from
the routi ng cl i ps on the rear brake fl ex hose and
chassi s brake tube.
(5) Remove the bol t attachi ng the wheel speed sen-
sor cabl e routi ng bracket to rear strut.
CAUTION: When removing a wheel speed sensor
from the rear disc brake adapter, do not use pliers
on the sensor head. This may damage the sensor
head. If the sensor has seized, use a hammer and a
punch to tap the edge of the sensor head ear, rock-
ing the sensor side-to-side until free.
(6) Remove the bol t attachi ng the wheel speed sen-
sor to the rear di sc brake adapter (Fi g. 22), then
careful l y remove the sensor head from the rear di sc
brake adapter and vehi cl e.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) I nstal l the wheel speed sensor head i nto the
di sc brake adapter (Fi g. 22).
(2) I nstal l the wheel speed sensor mounti ng bol t.
Ti ghten the mounti ng bol t to a torque of 12 N·m (105
i n. l bs.).
(3) I nstal l the wheel speed sensor cabl e routi ng
bracket on the rear strut.
(4) I nstal l wheel speed sensor cabl e i nto the rout-
i ng cl i ps on the rear brake hose and brake tube.
(5) Connect the wheel speed sensor cabl e connector
i nto vehi cl e wi ri ng harness (Fi g. 21). I nstal l the cl i p
attachi ng the wheel speed sensor cabl e connector to
vehi cl e’s body.
(6) I nstal l the ti re and wheel assembl y on vehi cl e.
(7) Lower the vehi cl e.
(8) Road test the vehi cl e to ensure proper opera-
ti on of the base brakes and ABS.
Fig. 21 Wheel Speed Sensor Connector
1 – FUEL TANK
2 – TENSION STRUT
3 – WHEEL SPEED SENSOR CONNECTOR
4 – LOCKING TAB
5 – CLIP
Fig. 22 Rear Wheel Speed Sensor
1 – RIGHT REAR WHEEL SPEED SENSOR
2 – TENSION STRUT
PL BRAKES 5 - 83
REMOVAL AND INSTALLATION (Continued)
DISASSEMBLY AND ASSEMBLY
INTEGRATED CONTROL UNIT
REMOVAL
NOTE: To replace the hydraulic control unit (HCU)
or the controller antilock brake (CAB) on this vehi-
cle, the entire integrated control unit (ICU) needs to
be removed from the vehicle. The CAB can then be
separated from the HCU. Do not attempt to replace
the CAB with the ICU mounted in the vehicle.
(1) Remove the I CU from the vehi cl e. Refer I NTE-
GRATED CONTROL UNI T i n the REMOVAL AND
I NSTALLATI ON secti on i n thi s secti on of the servi ce
manual .
(2) Di sconnect the pump/motor wi ri ng harness
(Fi g. 23) from the CAB.
(3) Remove the 4 bol ts (Fi g. 24) attachi ng the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fi g. 25).
INSTALLATION
(1) I nstal l the CAB (Fi g. 25) on the HCU.
(2) I nstal l the 4 bol ts mounti ng the CAB (Fi g. 24)
to the HCU. Ti ghten the CAB mounti ng bol ts to a
torque of 2 N·m (17 i n. l bs.).
(3) Pl ug the pump/motor wi ri ng harness i nto the
CAB (Fi g. 23).
(4) I nstal l the I CU i n the vehi cl e.
(5) Bl eed the base and ABS hydraul i c systems.
Refer to ANTI LOCK BRAKE SYSTEM BLEEDI NG
i n thi s secti on of thi s servi ce manual group.
(6) Road test the vehi cl e to ensure proper opera-
ti on of the base brakes and ABS.
Fig. 23 Pump/Motor To CAB Wiring Harness
1 – CAB
2 – PUMP MOTOR WIRING HARNESS
3 – PUMP MOTOR
4 – HCU VALVE BLOCK
Fig. 24 CAB Attaching Bolts
1 – MOUNTING BOLTS
2 – CAB
3 – HCU VALVE BLOCK
Fig. 25 Remove/Install CAB
1 – CAB
2 – HCU VALVES
3 – HCU VALVE BLOCK
5 - 84 BRAKES PL
SPECIFICATIONS
TONE WHEEL RUNOUT
FRONT TONE WHEEL:
Maxi mum Runout . . . . . . . . . 0.25 mm (0.009 i n.)
REAR TONE WHEEL:
Maxi mum Runout . . . . . . . . . 0.25 mm (0.009 i n.)
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE
FRONT WHEEL:
Mi ni mum Cl earance . . . . . . . 0.28 mm (0.011 i n.)
Maxi mum Cl earance . . . . . . . 1.42 mm (0.056 i n.)
REAR WHEEL:
Mi ni mum Cl earance . . . . . . . 0.45 mm (0.018 i n.)
Maxi mum Cl earance . . . . . . . 1.12 mm (0.044 i n.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts. . . . . . . . . . . . . . . 17 N·m (145 i n. l bs.)
MASTER CYLINDER:
Mounti ng Nuts . . . . . . . . . . 28 N·m (250 i n. l bs.)
POWER BRAKE BOOSTER:
Mounti ng Nuts . . . . . . . . . . 34 N·m (300 i n. l bs.)
DISC BRAKE CALIPER:
Cal i per Banjo Bol t . . . . . . . . . 48 N·m (35 ft. l bs.)
Gui de Pi n Bol ts . . . . . . . . . . 22 N·m (192 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . 15 N·m (125 i n. l bs.)
WHEEL CYLINDER (REAR):
Mounti ng Bol ts . . . . . . . . . . 13 N·m (115 i n. l bs.)
Bl eeder Screw . . . . . . . . . . . . 10 N·m (80 i n. l bs.)
DRUM BRAKE SHOE SUPPORT PLATE
(REAR):
Mounti ng Bol ts . . . . . . . . . . . 75 N·m (55 ft. l bs.)
DISC BRAKE ADAPTER (REAR):
Mounti ng Bol ts . . . . . . . . . . . 75 N·m (55 ft. l bs.)
HUB AND BEARING (REAR):
Retai ni ng Nut . . . . . . . . . . 217 N·m (160 ft. l bs.)
PARKING BRAKE:
Lever Mounti ng Nuts . . . . . 28 N·m (250 i n. l bs.)
TIRE AND WHEEL:
Wheel Mounti ng Nut . . . . . . . . . . . 109–150 N·m
(80–110 ft. l bs.)
INTEGRATED CONTROL UNIT:
Mounti ng Bol ts . . . . . . . . . . . 11 N·m (97 i n. l bs.)
CAB Mounti ng bol ts . . . . . . . . 2 N·m (17 i n. l bs.)
Bracket-to-Frame Rai l Bol ts . . . . . . . . . . 23 N·m
(200 i n. l bs.)
WHEEL SPEED SENSOR:
Head Mounti ng bol t . . . . . . 12 N·m (105 i n. l bs.)
PL BRAKES 5 - 85