WARNING > WARNING © warnine: Chryster LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. & caution Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing mineral oil fo clean the system components. These fluids damage rubber cups and seals. Use only fresh brake fluid or Mopar brake cleaner to clean or flush brake system components. These are the only cleaning materials recommended. if system contamination is suspected, check the fluid for dirt, discoloration, or separation into distinct layers. Also check the reservoir cap seal for distortion. Drain and flush the system with new brake fiuid if contamination is suspected. AQ caution: Use Mopar brake fluid, or an equivalent quality fluid meeting SAE/DOT standards J1703, and DOT 3, Brake fluid must be clean and free of contaminants, Use fresh fluid from sealed containers only to ensure proper antilock component operation. & CAUTION: Use Mopar multi-mileage or high temperature grease to lubricate caliper slide surfaces, drum brake pivot pins, and shoe contact points on the backing plates. Use multi-mileage grease or GE 661 or Dow 171 silicone grease on caliper slide pins to ensure proper operation. DESCRIPTION > EXCEPT SRT8 Dual piston disc brake calipers are used on the front. Single piston disc brake calipers are used on the rear. Ventilated disc brake rotors are used on the front. Solid rotors are standard on the rear, with @ heavy duty option using ventilated rotors.Power brake assist is supplied by a vacuum operated, dual diaphragm power brake booster. The master cylinder used for all applications has an aluminum body and nylon reservoir with single filer cap. A fluid level indicator is mounted to the side of the reservoir. The braking force of the rear wheels is controlled by Electronic Brake Distribution (EBD). The EBD functions like @ rear proportioning valve. The EBD system uses the Anti-lock Brake System (ABS) system to control the slip of the rear wheels in partial braking range. The braking force of the rear wheels is controlled electronically by using the inlet and outlet valves located in the Hydraulic Control Unit (HCU) Factory installed brake linings on all models consists of organic base material combined with metallic particles, DESCRIPTION > SRT8 (") note: SRT8 calipers are not serviceable. Do not attempt disassembly. ‘SRT8 models utilizes high performance four-wheel disc brakes. All brake calipers are opposed fixed design manufactured by Brembo®, All brake rotors are the intemal vented type, All SRTS calipers mount directly to the knuckle. They do not use brake caliper adapters. ‘The SRTS rear brake rotors have integrated parking brake drums like the standard rear disc brake system Each front brake caliper features six pistons, three in each outer half of the caliper. The two outer halves of this caliper connect hydraulically using internal passageways. Each caliper half has its own bleeder screw at the top and must be bled individually when bleeding is required. Each rear brake caliper features four pistons, two in each half of the caliper. The two halves of the caliper are connected hydraulically by means of an extemal brake tube located on the bottom of the caliper assembly. Each caliper half has its own bleeder screw at the top and must be bled individually when bleeding is required. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM Base brake components consist of the brake shoes, calipers, rear park brake drums/rotors, front brake rotors, brake lines, master cylinder, booster, HCU and parking brake shoes. Brake diagnosis involves determining ifthe problems related to a mechanical, hydraulic, electrical or vacuum operated component.DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > PRELIMINARY BRAKE CHECK 4. Check condition of tires and wheels. Damaged wheels and worn, damaged, or underinflated tires can cause pull, shudder, vibration, and a coneition similar to grab. 2. If complaint was based on noise when braking, check suspension components. Jounce front and rear of vehicle and listen for noise that might be caused by loose, worn or damaged suspension or steering components. 3. Inspect brake fluid level and condition, Note that the brake reservoir fiuid level will decrease in proportion to normal ining wear. Also note that brake fluid tends to darken over time. This is normal and should not be mistaken for contamination. a. If fluid level is abnormally low, look for evidence of leaks at calipers, brake lines, master cylinder, and HCU. b. If fluid appears contarrinated, drain out a sample to examine. System will have to be flushed if fluid is separated into layers, of contains a substance other than brake fluid. The system seals, cups, hoses, master cylinder, and HCU will also have to be replaced after flushing. Use clean brake fluid to flush the system. 4, Check parking brake operation, Verify free movement and full release of cables and lever. Also note if vehicle was being operated with parking brake partially applied, 5. Check brake pedal operation. Verify that pedal does not bind and has adequate free play. If pedal lacks free play, check pedal and power booster for being loose of for bind coneition. Do not road test until condition is corrected, 6. Check booster vacuum check valve and hose. 7. If components checked appear OK, road test the vehicle. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING 4. If complaint involved low brake pedal, pump pedal and note if it comes back up to normal height 2. Check brake pedal response with transmission in neutral and engine running. Pedal should remain firm under constant foot pressure. 3. During road test, make normal and firm brake stops in 25-40 mph range. Note faulty brake operation such as low pedal, hard pedal, fade, pedal pulsation, pull, grab, drag, noise, etc. 4. Attempt to stop the vehicle with the parking brake only (do not exceed 25 mph) and note grab, drag, noise, etc.ROAD TESTING > PEDAL FALLS AWAY Abrake pedal that falls away under steady foot pressure is generally the result of a systemleak. The leak point could be at a brake line, fitting, hose, or caliper. If leakage is severe, fluid will be evident at or around the leaking component. Internal leakage (seal by-pass) in the master cylinder caused by worn or damaged piston cups, may also be the problem cause, An internal leak in the ABS system may also be the problem with no visual fluid leak. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > LOW PEDAL If a low pedal is experienced, pump the pedal several times. If the pedal comes back up, the most likely causes are wom linings, rotors, or calipers are not sliding on the slide pins. The proper course of action is to inspect and replace all worn component. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > SPONGY PEDAL A spongy pedal is most often caused by air in the system. However substandard brake hoses can cause a spongy pedal. The proper course of action is to bleed the system, and replace substandard quality brake hoses if suspected DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > HARD PEDAL OR HIGH PEDAL EFFORT Ahard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or badly worn. The power booster, check valve, check valve sealigrommet or vacuum leak could also cause a hard pedal or high pedal effort DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > PEDAL PULSATION Pedal pulsation is caused by components that are loose, or beyond tolerance limits ‘The primary cause of pulsation are disc brake rotors with excessive lateral runout or thickness variation. Other causes are loose wheel bearings or calipers and wom, damaged tires,(°) NoTE: ‘Some pedal pulsation may be felt during ABS activation. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > BRAKE DRAG Brake drag occurs when the lining is in constant contact with the rotor or drum. Drag can occur at one Wheel, all wheels, fronts only, or rears only. Drag is a product of incomplete brake release. Drag can be minor or severe enough to overheat the linings, rotors and park brake drums. Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in rotors and park brake drums from the overheat-cool down process. In most cases, the rotors, wheels and tires are quite warm to the touch after the vehicle is stopped. ‘Severe drag can char the brake lining al the way through. It can also distort and score rotors to the point of replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the lining may generate smoke as it chars from overheating, Common causes of brake drag are: + Parking brake partially applied. * Loose/worn wheel bearing * Seized caliper. + Caliper binding, + Loose caliper mounting. + Mis-assembled components, ‘+ Damaged brake lines, If brake drag occurs at the front, rear or all wheels, the problem may be related to a blocked master cylinder retum port, faulty power booster (binds-does not release) or the ABS system. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > BRAKE FADE Brake fade is usually @ product of overheating caused by brake drag. However, brake overheating and resulting fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a short time span, or constant braking on steep mountain roads. Refer to BRAKE DRAG for causes.DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > BRAKE PULL Front brake pull condition could result from. # Contaminated lining in one caliper + Seized caliper piston * Binding caliper + Loose caliper + Rusty caliper slide surfaces + Improper brake shoes « Damaged rotor + Wheel alignment. + Tire pressure ‘Awom, damaged wheel bearing or suspension component are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull ‘common and frequently misdiagnosed pull condition is where direction of pull changes after a few stops. The cause is a combination of brake drag followed by fade at one of the brake units As the dragging brake overheats, efficiency is so reduced that fade occurs. Since the opposite brake unit is still functioning normally, its braking effect is magnified. This causes pull to switch direction in favor of the normally functioning brake unit ‘An additional point when diagnosing a change in pull condition concerns brake cool down. Remember that pull will return to the original direction, if the dragging brake unit is allowed to cool down (and is not seriously damaged) DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > REAR BRAKE DRAG OR PULL Rear drag or pull may be caused by improperly adjusted park brake shoes or seized parking brake cables, contaminated lining, bent or binding shoes or improperly assembled components. This is particularly true when only one rear wheel is involved. However, when both rear wheels are affected, the master cylinder or ABS system could be at fault DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLEScontaminated, cleaning and or replacement will be necessary. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > BRAKE LINING CONTAMINATION Brake lining contamination is mostly a product of leaking calipers or worn seals, driving through deep water puddles, or lining that has become covered with grease and grit during repair. Contaminated lining should be replaced to avoid further brake problems, DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > ROAD TESTING > WHEEL AND TIRE PROBLEMS ‘Some conditions attributed to brake components may actually be caused by a wheel or tire problem, ‘A damaged wheel can cause shudder, vibration and pull. A worn or damaged tire can also cause pull. *) NOTE: Propshaft angle can also cause vibration/shudder. Severely worn tires with very ite tread lett can produce a grab-like condition as the tire loses and recovers traction. Flat-spotted tires can cause vibration and generate shudder during brake operation. Tire damage such as a severe bruise, cut, ply separation, low alr pressure can cause pull and vibration. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > BRAKE NOISES ‘Some brake noise is common on some disc brakes during the first few stops after a vehicle has been parked overnight or stored. This is primarily due to the formation of trace corrosion (light rust) on metal surfaces. This light corrosion is typically cleared from the metal surfaces after a few brake applications Causing the noise to subside. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > BRAKE NOISES > BRAKE SQUEAK/SQUEAL Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oll. Glazed linings and rotors with hard spots can also contribute to squeak. Dirt and foreign meterial embedded in the brake lining will also cause squeak/squeal. Avery loud squeak or squeal is frequently a sign of severely worn brake lining. If the lining has worn(°) NoTE: The front outer brake shoes are equipped with a wear indicator. The indicator will produce an audible noise when it contacts the rotor surface. DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > BRAKE NOISES > BRAKE CHATTER Brake chatter is usually caused by loose or worn components, or glazed/burnt lining, Rotors with hard spots can also contribute to chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining, DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM > BRAKE NOISES > THUMP/CLUNK NOISE ‘Thumping or clunk noises during braking are frequently not caused by brake components. In many cases, such noises are caused by loose or damaged steering, suspension, or engine components. STANDARD PROCEDURE > MANUAL BLEEDING [2] NOTE: Do not use this procedure if the master cylinder, Hydraulic Control Unit (HCU), brake ‘booster, or the lines between the master cylinder and the HCU have been replaced. if any of these components are replaced perform the PRESSURE BLEEDING procedure Use Mopar® brake fiuid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times, Do not allow the master cylinder to run out of fluid during bleed operations. An emoty cylinder will allow additional air to enter the system. Check the cylinder fluid level frequently and add fluid as needed,Fig 1: Bleed Hose Setup J8905-18, Courtesy of CHRYSLER GROUP LLC Bleed only one brake component at a time in the following sequence: 1. Fill the master cylinder reservoir with brake fluid. 2. If the calipers are overhauled, open the caliper bleed screws. Then close each bleed screw as. fluid starts to drip from it. Top off the master cylinder reservoir once more before proceeding. 3. Attach one end of the bleed hose (1) to the bleed screw and insert the opposite end in a suitable container (2) partially filled with brake fluid. Be sure the end of the bleed hose is immersed in fluidSTANDARD PROCEDURE > PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Fill the master cylinder reservoir with brake fluid prior to connecting pressure bleeder. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding, [*) Nore: Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally. a tank pressure of 51-67 kPa (15-20 psi) is sufficient for bleeding. Connect the pressure bleeder to the master cylinder using adapter provided with the equipment or MASTER CYLINDER CAP (special tool #6921, Cap, Master Cylinder), When pressure bleeding, a helper is needed inside the vehicle. Bleed only one brake component at a time beginning with the rear brake caliper furthest from the master cylinder, then the other rear caliper, followed by the furthest front caliper from the master cylinder and finishing with the closest to the master cylinder as follows’Fig 1: Bleed Hose Setup J8905-18, Courtesy of CHRYSLER GROUP LLC 1. Attach one end of a clear bleed hose (1) to the bleed screw and insert the opposite end in a suitable container (2). 2. Open the bleeder and have the helper pump the brake pedal multiple times ,, unti the fluid stream is clear and free of air bubbles, then with the brake pedal pushed, tighten the bleeder screw, 3. Repeat step 2 on each wheel until all are complete, 4. Remove the bleeder hose, and the pressure bleeder from the master cylinder.If the Hydraulic Control Unit (HCU) was replaced, the ABS System Bleeding procedure must now be preformed. Refer to STANDARD PROCEDURE 5. Verify the brake pedal is operating properly. SPECIFICATIONS > SPECIFICATIONS (*] Nore: When refacing a rotor, the required TIR (Total indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning (machining) equipment is required. LIMITS/SPECIFICATIONS - 17 INCH BRAKES (BASE) Brake Rotor Rotor Thickness Minimum Rotor Thickness Front 32mm 30.5 mm 1.26 in 4.200 in, Rear 14mm 12.5 mm 55 in 492 in. * TIR Total Indicator Reading (Measured On Vehicle) LIMITS/SPECIFICATIONS - 18 INCH BRAKES (PREMIUM) Brake Rotor Rotor Thickness Minimum Rotor Thickness Front 22 mm 30.5 mm 1.26 in. 1.200 in. Rear 22 mm 20.5 mm 87 in. 807 in. * TIR Total Indicator Reading (Measured On Vehicle) LIMITS/SPECIFICATIONS - SRTB Brake Rotor Rotor Thickness Minimum Rotor Thickness: Rotor Thickness. Variation 009 mm 00036 in, 00g 00036 in, Rotor Thickness. Variation 009 mm 00036 in, 009 00036 in, Rotor Thickness Variation, Rotor Runout * 05 mm 002 in. 05 mm 002 in. Rotor Runout * 05 mm 002 in. 05 mm 002 in. Rotor Runout *28 mm 26 mm 010 03 mm Rear 4.10in 4.02 in 00038 in 004 in * TIR Total Indicator Reading (Measured On Vehicle) ‘SPECIFICATIONS > TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION Nam Ft. Lbs. In, Lbs. Brake Pedal Bracket To Dash 20 16 7 Brake Booster Mounting Nuts 20 16 WwW Backing Plate Bolts 23 - 16 Master Cylinder Mounting Nuts 25 8 224 Master Cylinder Brake Line 19 - 168 (Both Front Caliper Slide Bolts (Guide 55 41 - Pins) Brake Line Fittings (All) 19 - 168 Front Caliper Adapter Bolts to 200 148, - Knuckle, Except SRT Front Caliper Bolts to Knuckle, Een 200 148 - Front Caliper Center Bolt to ie Sone 32.5 24 288 Front Caliper Brake Hose Banjo 30 23 265 Bot Front Caliper Bleed Screw 16 : 141.5 Parking Brake Lever Bolts/Nuts 24 18 212 Power Steering Reservoir Bolt 20 18 Ww Rear Caliper Adapter Bolts to Knuckle, Except SRTS 120 88 . Rear Caliper Botts to Knuckle, one 120 89 - Rear Caliper Slide Bolts 275 20 283 Rear Caliper Brake Hose Banjo 30 22 265 Bolt‘Vacuum Pump Bracket to 55 a - Engine SPECIAL TOOLS > SPECIAL TOOLS 10301 - Remover, Rear Park Brake Cable 6921 - Cap, Master Cylinder (Originally Shipped In Kit Number(s) 6907.) \ 8280 - Installer, Dust Boot Koy (Originally Shipped In Kit Number(s) 8283, 8283CC, 8527, Z 8527CC.) C-3919 - Gauge, Brake Shoes (C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.)Fig 1: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End Coutesy of CHRYSLER GROUP LLC [f) Nore: Only the 3.6L engine has an electric vacuum pump. ‘On the 3.6L engine there is an electric vacuum pump (4) located on the front of the engine under the alr cleaner body, directly above the idler pulley. The vacuum pump (4) has one electrical connector (3) on a pigtail connected to the mounting bracket (1). The vacuum pump (4) mounts to the bracket (1) with two rubber insulated studs to reduce vibration, and the bracket (1) mounts to the intake manifold with two bolts (2). The vacuum hose has a quick-connect type end (6) with a locking tab (5) at the vacuum pump (4),The Electric Vacuum Pump (EVP) system is installed to provide supplemental vacuum to the brake booster when the engine vacuum supply is low. The vacuum pum is connected to the engine and the brake booster through a series of hoses and one-way flow check valves. A pressure senor, mounted in the brake booster, provides information to the Antilock Brake System (ABS) module, then the vacuum level is sent over CAN to the Powertrain Control Module (PCM). The PCM modulates the EVP operation to maintain the brake booster vacuum within a given range. This system ensures that the customer experiences a consistent brake pedal feel under all driving conditions. Atwo wire electrical connector is used to supply power and ground for the vacuum pump. Operating voltage Is between 9V - 16V. Control of the vacuum pump is provided by the Powertrain Control Module (PCM) using a low side driver to a normally open relay (coil side). The relay coil side power is froma fuse In the under hood PDC. The switched power circuit to the vacuum pump relay is wired directly from the battery through an inline fuse holder located below the remote battery post connection on the RH side in the engine compartment. The relay is located on the LH shock tower in the engine compartment. The PCM monitors the Manifold Absolute Pressure (MAP) sensor and when the signal indicates low engine vacuum the PCM will eycle the vacuum pump as necessary to add vacuum to the power brake booster. The vacuum hoses are connected between the vacuum pump, the engine manifold (for MAP sensor signal), and the power brake booster vacuum sensor (on the brake booster). When the PCM cycles the vacuum pump on, the PCM monitors the MAP sensor and if the vacuum signal does not indicate a rising vacuum then DTCs will be set. Additionally, the Antilock Brake System (ABS) module monitors the vacuum at the brake booster vacuum sensor and DTCs will also set in the ABS module. ELECTRICAL > PUMP, ELECTRIC VACUUM > REMOVAL > REMOVALFig 1: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End Coutesy of CHRYSLER GROUP LLC 1. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL - 3.0L , BODY, AIR CLEANER, REMOVAL - 3.0L Turbo Diesel , BODY, AIR CLEANER, REMOVAL - 3.6L , BODY, AIR CLEANER, REMOVAL - 5.7L or BODY, AIR CLEANER, REMOVAL - 6.4L 2, Disconnect the electrical connector (3) and remove the harness connector from the mounting bracket (1), 3. Release the locking tab (5) and disconnect the quick connect vacuum hose (6) from the vacuum pump (4), 4, Remove the vacuum pump bracket bolts (2) and remove the vacuum pump assembly from the vehicle.Fig 1: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End Coutesy of CHRYSLER GROUP LLC 4. Position the vacuum pump assembly (4), install the bracket mounting bolts (2) and torque to 55 Nim (41 ft. Ibs.) 2. Attach the harness connector to the bracket (1), and connect the electrical connector (3). 3. Connect the quick-connect vacuum hose (6) to the vacuum pump (4) and seat the locking tab 6). 4. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION - 3.0L , BODY, AIR CLEANER, INSTALLATION - 3.0L Turbo Diesel , BODY, AIR CLEANER, INSTALLATION - 3.6L. , BODY, AIR CLEANER, INSTALLATION - 5.7L or BODY, AIR CLEANER, INSTALLATION - 6.4LFig 1: Brake Fluid Level Sensor Electrical Connector, Reservoir & Screw ~~ ad Cay RGROUP Lc 1. Disconnect the electrical connector from the brake fluid level sensor (1).Fig 2: Sensor Locking Tabs Coutesy of CHRYSLER GROUP, LLC 2. From the opposite side of the master cylinder reservoir release the sensor locking tabs (1) with a small screw driver. 3. Pull the sensor (1) out of the reservoir. ELECTRICAL > SWITCH, BRAKE FLUID LEVEL > INSTALLATION > INSTALLATIONFig 1: Brake Fluid Level Sensor Electrical Connector, Reservoir & Screw Cay ISLER GROUP, LLC 4. Install the sensor (1) with a new O-ring into the reservoir (2) until the locking tabs are engaged 2. Install the wire connector to the fluid level sensor (1). ELECTRICAL > SWITCH, RED BRAKE WARNING INDICATOR > DESCRIPTION > DESCRIPTION Ared warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. ELECTRICAL > SWITCH, RED BRAKE WARNING INDICATOR > OPERATION >‘The lamp is tumed on momentarily when the ignition switch is turn to the on position. This is a self test to verify the lamp Is operational The red warning light alerts the driver if the fluid level is low or the parking brakes are applied. A red warning lamp with an amber warning lamp may indicate a electronic brake distribution fault ELECTRICAL > SWITCH, RED BRAKE WARNING INDICATOR > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - RED WARNING LAMP. ‘The red warning lamp illuminates when the parking brake is applied or when the fluid level in the master cylinder is low. It will also illuminate at start up as part of a bulb check. Ifthe light comes on, first verify that the parking brakes are fully released. Then check pedal action and {ud level. If problem is confirmed, inspect the brake hydraulic system for leaks. ‘Ared warning lamp with a amber warning lamp may indicate a electronic brake distribution fault HYDRAULIC/MECHANICAL > ADAPTER, DISC BRAKE CALIPER > REMOVAL > REMOVAL | NOTE: Front caliper adapter shown, rear caliper adapter similar.Fig 1: Brake Caliper Tension Clip Courtesy of CHRYSLER GROUP LLC 1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE 2. Remove the front wheel and tire assembly. 3. Bottom caliper pistons into the caliper. 4, Remove the brake caliper tension clip (1) by pressing rearward on the front of the clip (2) while pling the clip out (3) from the caliper.Fig 2: Brake Caliper, Adapter, Adapter Bolts & Guide Pins Coutesy of CHRYSLER GROUP, LLC 5. Remove the caliper slide dust btt shields and loosen the brake caliper slide bots (Quide pins) (2). & caution Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result Provide a suitable support to hang the caliper securely. 6. Remove the brake caliper (3) from the caliper adapter (4) and hang the brake caliper (3) 7. Remove the brake caliper adapter mounting bolts (1) and remove adapter (4) from the vehicle. HYDRAULIC/MECHANICAL > ADAPTER, DISC BRAKE CALIPER > INSTALLATION >"| NOTE: Front caliper adapter shown, rear caliper adapter similar. Fig 1: Brake Caliper, Adapter, Adapter Bolts & Guide Pins (Courtesy of CHRYSLER GROUP, LL 1, Position the brake caliper adapter (4), install the brake caliper adapter mounting bolts (1) and tighten to: a. Front - 200 N.m (148 ft. Ibs.) b, Rear - 120 N.m (89 ft. Ibs.)NOTE: Brake caliper slide bolts (guide pins) (2) should be free from debris 2. Position the brake caliper (3), install the brake caliper slide bolts (guide pins) (2) and tighten to: a, Front - 55 N.m (41 ff. Ibs.) b. Rear - 27.5 N.m(20 ft. Ibs.) 3. Install the caliper slide dust bolt shields. Fig 2: Brake Caliper Tension Clip (Courtesy of CHRYSLER GROUP, 4. Install the brake caliper tension clip (1) 5. Install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE . 6. Pump brake pedal until caliper pistons and brake pads are seated and a firm brake pedal isHYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > DESCRIPTION > DESCRIPTION Fig 1: Identifying Power Brake Booster/Master Cylinder Components e1aTabe Coutesy of CHRYSLER GROUP LLC 1-PUSH ROD 2. BOOSTER MOUNTING STUDS 3- POWER BRAKE BOOSTER 4- FLUID RESERVOIR 5 - MASTER CYLINDER7 - CHECK VALVE GROMMET The booster assembly consists of a housing divided into separate chambers by two internal diaphragms. The outer edge of each diaphragm is attached to the booster housing (3). ‘Two push rods are used in the booster. The primary push rod (1) connects the booster to the brake pedal. The secondary push rod connects the booster to the master cylinder to stroke the cylinder pistons. HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > OPERATION > OPERATION Fig 1: Identifying Power Brake Booster/Master Cylinder Components Coutesy of CHRYSLER GROUP LLC1 - PUSH ROD 2.- BOOSTER MOUNTING STUDS 3+ POWER BRAKE BOOSTER 4- FLUID RESERVOIR 5 - MASTER CYLINDER 6 - FLUID LEVEL SENSOR 7+ CHECK VALVE GROMMET ‘The atmospheric inlet valve is opened and closed by the primary push rod. Booster vacuum supply is through a hose attached to an intake manifold fitting at one end and to the booster check valve (7) at the other, The vacuum check valve in the booster housing is a one-way device that prevents vacuum leak back. Power assist is generated by utilizing the pressure differential between normal atmospheric pressure and a vacuum. The vacuum needed for booster operation is taken directly from the engine intake manifold The entry point for atmospheric pressure is through a filter and inlet valve at the rear of the housing. The chamber areas forward of the booster diaphragms are exposed to vacuum from the intake manifold, ‘The chamber areas to the rear of the diaphragms, are exposed to normal atmospheric pressure of 101.3 kilopascals (14.7 pounds/square in.) Brake pedal application causes the primary push rod (1) to open the atmospheric inlet valve. This exposes the area behind the diaphragms to atmospheric pressure. The resulting pressure differential provides the extra apply force for power assist. ‘The booster check valve, check valve grommet (7) and booster seals are serviceable. HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER 1, Start the engine and check the booster vacuum hose connections. A hissing noise indicates a vacuum leak. Correct any vacuum leaks before proceeding. 2. Stop the engine and pump the brake pedal until all vacuum reserve in the booster is depleted. 3. Press and hold the brake pedal under light foot pressure. The pedal should hold firm. If the pedal fais away, there may be an extemal leak or the master cylinder is faulty (intemal leakage). 4, Start the engine and note pedal action. It should fall away slightly under light foot pressure, then hold firm. If no pedal action is discemible, the power booster, vacuum supply or vacuum check valve is faulty, proceed to POWER BOOSTER VACUUM TEST 5. If the POWER BOOSTER VACUUM TEST passes, rebuild the booster vacuum reserve as follows: Release the brake pedal. Increase engine speed to 1500 RPM, close the throttle and immediately turn off the ignition to stop the engine.more vacuum assisted pedal applications. If the vacuum assist is not provided, the booster is fauty. HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER > POWER BOOSTER VACUUM TEST 1. Connect a vacuum gauge to the booster check valve with a short length of hose and T-ftting 2. Start and run the engine at curb idle for one minute. 3. Observe the vacuum supply. If the vacuum supply is less that 12 inches HG (406 milibars), repair the vacuum supply. 4. Clamp the hose shut between the intake vacuum source and the check valve. Stop the engine and observe the vacuum gauge. 6. If the vacuum drops more than one inch HG (33 millibars) within 15 seconds, the booster diaphragm or check valve is faulty. HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER > POWER BOOSTER CHECK VALVE TEST 1. Remove the power booster check valve from the power booster. 2. Using a hand operated vacuum pump, apply 15-20 inches HG (608-677 milibars) vacuum at the booster side of the check valve, 3. The vacuum should hold steady. If the gauge on the pump indicates vacuum loss, the check valve is faulty and should be replaced, HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > REMOVAL > REMOVAL & caution: Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent power brake booster from ‘sucking in any contamination as master cylinder is removed. This can be done simply by pumping brake pedal, with vehicle engine not running and the ignition OFF, until a firm feeling brake pedal is achieved.2. Disconnect and isolate the negative battery cable. 3. For vehicles equipped with a 5.7L engine, 1, Remove the engine cover. 2. Remove the air inlet hose resonator 4. Remove the air cleaner assembly. Refer to AIR CLEANER, REMOVAL - 3.0L , AIR CLEANER, REMOVAL - 3.0L Turbo Diesel , AIR CLEANER, REMOVAL - 3.6L , AIR CLEANER, REMOVAL - 5.7L or AIR CLEANER, REMOVAL - 6.4L. Fig 1: Power Steering Reservoir (Courtesy of CHRYSLER GROUP, LLG 5. Remove the power steering reservoir (1) from the bracket and position it aside. 6. Remove the cowl panel cover and cowl side extensions. Refer to COVER, COWL PANEL, REMOVALFig 2: Wire Connector & Brake Fluid Level Sensor Coutesy of CHRYSLER GROUP, LLC 7. Disconnect the fluid level sensor (3) electrical connector (2). 8. Disconnect the power booster vacuum hose and vacuum sensor (4). 9. Detach the wiring harness from the shock tower.Fig 3: Vacuum Hose And Check Valve osesosz2ax Coutesy of CHRYSLER GROUP, LC 410. Disconnect the vacuum hose and check valve (1) from the brake booster.Fig 4: Brake Tube Support 0508052264 Coutesy of CHRYSLER GROUP, LC 11, Detach the brake tube support on the left shock tower (1).Fig 5: Master Cylinder And Brake Tubes oas0s278s Coutesy of CHRYSLER GROUP, LC Q cauTiON: Use extreme care not to damage the brake tubes when relocating the master oylinder. & caution: Use extreme care not to scratch or damage the master cylinder piston. 12, Remove and discard the two master cylinder nuts. Separate the master cylinder from the booster and carefully position the master cylinder (1) aside.Fig 6: Master Cylinder Piston Coutesy of CHRYSLER GROUP, LC 13. Protect the master cylinder piston (1) after removal 414, Remove the wiper motor and linkage assembly. Refer to LINKAGE, WIPER ARM, REMOVAL 15. Remove the steering colurm opening cover. Refer to COVER, STEERING COLUMN. OPENING, REMOVALFig 7: Retainer Clip, Booster Push Rod, Brake Booster Mounting Nuts & Booster Lif DK IY Z 2797711 Coutosy of CHRYSLER GROUP, LLC 16. Remove and discard the retainer clip (2) that holds the booster push rod (4) on the pedal pin. ‘Separate the push rod from the pedal pin. 17. Loosen the brake light switch bracket and relocate 18. Remove and discard the four power brake booster nuts (3).Fig 8: Power Brake Booster Coutesy of CHRYSLER GROUP, LC 49. Remove the power brake booster (1) from the vehicle. HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > INSTALLATION > INSTALLATIONFig 1: Power Brake Booster 0508052287 Courtesy of CHRYSLER GROUP LLC 1. Position the brake booster (1) in the vehicleFig 2: Retainer Clip, Booster Push Rod, Brake Booster Mounting Nuts & Booster r¥ 2797711 Coutosy of CHRYSLER GROUP, LLC 2. Inside the vehicle, lubricate the pedal pin with Mopar muiti-mileage grease 3. Install the four brake booster nuts (3) and tighten to the proper (Torque Specifications) 4. Slide the booster push rod (4) on pedal pin and secure the rod to the pin with a new retainer clip (2), 5. Install the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING, INSTALLATION 6. Install the wiper motor and linkage assembly. Refer to SPECIFICATIONS:Fig 3: Master Cylinder Piston Coutesy of CHRYSLER GROUP, LC 7. Carefully position the master cylinder (1) to the power brake booster. Install the two NEW master cylinder nuts and tighten to the proper (Torque Specifications).Fig 4: Brake Tube Support 0508052264 Coutesy of CHRYSLER GROUP, LC 8. Attach the brake tube (1) on the left shock tower.Fig 5: Vacuum Hose And Check Valve osesosz2ax Coutesy of CHRYSLER GROUP, LC 9. Connect the vacuum hose and check vaive (1) to the brake booster.Fig 6: Wire Connector & Brake Fluid Level Sensor Coutesy of CHRYSLER GROUP, LLC 10. Connect the vacuum sensor (4). 11. Connect the fluid level sensor (3) electrical connector (2). 12. Install the cowl panel cover and cowl side extensions. Refer to COVER, COWL PANEL, INSTALLATIONFig 7: Power Steering Reservoir Coutesy of CHRYSLER GROUP, LC 13. Install the power steering reservoir (1) to the bracket and tighten to the proper (TORQUE SPECIFICATIONS ) 14. Install the air cleaner assembly. Refer to AIR CLEANER, INSTALLATION - 3.0L, AIR CLEANER, INSTALLATION - 3.0L Turbo Diesel , AIR CLEANER, INSTALLATION - 3.6L, AIR CLEANER, INSTALLATION - 5.7L or AIR CLEANER, INSTALLATION - 6.4L . 15. For vehicles equipped with a 5.7L engine, 1. Install the engine cover. 2. Install the air inlet hose resonator. 46. Connect the negative battery cable. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > DESCRIPTION >calipers are free to slide laterally, this allows continuous compensation for ining wear. ‘SRTB The SRT@ models utilize high performance four-wheel disc brakes. These calipers are not serviceable. Do not attempt disassembly. All SRT brake calipers are opposed fixed design manufactured by Brembo®. All SRTE calipers mount directly to the knuckle and do not use brake caliper adapters. The front brake caliper features six pistons, three in each outer half of the caliper. The two outer halves of this caliper connect hydraulically using internal passageways. Each caliper half has its ‘own bleeder screw at the top and must be bled individually when bleeding is required. The rear brake caliper features four pistons, two in each half of the caliper. The two halves of the caliper are connected hydraulically by means of an external brake tube located on the bottom of the caliper assembly. Each caliper half has its own bleeder screw at the top and must be bled individually when bleeding is required. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > OPERATION > OPERATION EXCEPT SRT8 When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor. in summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston, Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero, The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the ‘amount of piston extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad SRT8_All SRTS brake calipers are opposed fixed design manufactured by Brembo®. These calipers. are not serviceable. Do not attempt disassembly. The calipers are solid mounted to the knuckles meaning the calipers do not move (slide) as in conventional brake calipers. When the brakes are applied fluid pressure is exerted against the caliper pistons on both sides of the caliper equally. In summary, fluid pressure acting simultaneously on all pistons on both sides of the caliper produces a strong clamping action, When sufficient force is applied, friction will attempt to stop the rotors from turing and bring the Vehicle to @ stop. Application and release of the brake pedal generates only a very slight movement of the pistons. Upon release of the pedal, the pistons return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection Generally the amount is just enough to maintain contact between the piston the brake pad.by means of an external brake tube located on the bottom of the caliper assembly. All SRTB calipers, have two bieeder screws, one on the inboard half and one on the outboard half of the caliper and must. be bled individually when bleeding is required, HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > REMOVAL > ALL EXCEPT SRTB8 [?] NOTE: Front brake caliper shown, rear calipers similar. 4. Drain small amount of fluid from the master cylinder brake reservoir with a clean suction gun, 2. Install a prop rod on the brake pedal to keep pressure on the brake system, Holding the pedal inthis position will isolate the master cylinder from the hydraulic brake system and will not allow brake fluid to drain out of the brake fluid reservoir while the brake lines are open. This will allow you to bleed out the area of repair instead of the entire system 3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 4, Remove the wheel and tire assembly.Fig 4: Brake Caliper Tension Clip Coutesy of CHRYSLER GROUP, LC 5, Bottom the caliper pistons into the caliper. 6. Remove the brake caliper tension clip (1) by pressing rearward on the front of the clip (2) while puling the clip out (3) from the caliper.Fig 2: Caliper, Banjo Bolt, Brake Hose & Guide Pins Coutesy of CHRYSLER GROUP, LLC 7. Remove the brake hose banjo bolt (4) and gasket washers. Discard the gasket washers. 8. Remove the caliper slide dust bolt shields and loosen the brake caliper slide botts (guide pins) a. 9. Remove the caliper (2) from the adapter. 10. Remove and transfer any necessary components. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > REMOVAL > FRONT - SRT8 *) NOTE: These calipers are not serviceable. Do not attempt disassembly.(°) NoTE: Views are typical 1, Disconnect and isolate the battery negative cable 2. Install a prop rod on the brake pedal to keep pressure on the brake system, Holding the pedal in this position will isolate the master cylinder from the hydraulic brake system and will not allow brake fluid to drain out of the brake fluid reservoir while the brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 4, Remove the tire and wheel assembly. Fig 1: Caliper Mounting Bolts, Banjo Bol & Brake Hose osas096589 (Courtesy of CHRYSLER GROUP, LLG 5. Remove the banjo bolt (3) connecting the flexible brake hose (2) to the caliper. There are two sealing washers (one on each side of the hose fitting) that will come off when bolt is removed.Q CAUTION: When pushing pistons back into caliper bores, use only a trim stick as shown or other suitable soft tool. Never use screwdriver or other metal pry bar due to potential damage to braking surface of rotor, caliper, pistons or dust boots. 6. Place a trim stick between the brake pad and the outer edge of rotor. 7. Using a trim stick, slowly apply pressure against the brake pad unti all pistons (on that side of caliper) are completely bottomed in the bores of the caliper half. [°) Nore: Repeat above procedure to opposite brake pad and pistons as necessary. 8. Remove the caliper mounting bolts (1) 9. Remove the rake caliper with pads from the knuckle and brake rotor. 10. If the brake pads need to be removed from the caliper. Refer to PADS AND/OR SHOES, BRAKE, REMOVAL HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > REMOVAL > REAR - SRT8 (°) nore: These calipers are not serviceable. Do not attempt disassembly. () Nore: Views are typical 1, Disconnect and isolate the battery negative cable. 2. Install a prop rod on the brake pedal to Keep pressure on the brake system, Holding the pedal in this position will isolate the master cylinder from the hydraulic brake system and will not allow brake fluid to drain out of the brake fluid reservoir while the brake lines are open. This will allow you to bleed out the area of repair instead of the entire system, 3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .Fig 4: Rear Brake Caliper, Caliper Bolt, Banjo Bolt & Flexisble Brake Hose Coutesy of CHRYSLER GROUP, LC Remove the banjo bott (2) connecting the flexible brake hose (3) to the caliper (4). There are two sealing washers (one on each side of hose fitting) that will come off when the bolt is removed. Discard these washers; install NEW washers on installation. (CAUTION: When pushing pistons back into caliper bores, use only a trim stick as shown or other suitable soft tool. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor, caliper, pistons or dust boots. Place a trim stick between the brake pad and the outer edge of rotor. Using trim stick, slowly apply pressure against the brake pad until both pistons (an that side of the caliper) are completely bottomed in the bores of the caliper half. Remove the lower and upper caliper mounting bolts (1).10. If the brake pads (5) need to be replaced from caliper. Refer to PADS AND/OR SHOES, BRAKE, REMOVAL . HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > DISASSEMBLY > DISASSEMBLY Fig 1: Clamping Block Of Wood Over Caliper Piston (Courtesy cf CHRYSLER GROUP, LLC. 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston:Fig 2: Wrapping Wood Block With Shop Towels to Protect Caliper Piston Coutesy of CHRYSLER GROUP, LLC 3, Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and, protect caliper piston during removal & caution: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. © warnine: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.first piston removed, This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston, 7. Remove the second piston using the same procedure with short bursts of low pressure air Fig 3: Removing Piston Dust Boots (Coutesy of CHRYSLER GROUP. LLC 8, Remove piston dust boots (2) with a suitable pry toolFig 4: Removing Piston Seals Coutesy of CHRYSLER GROUP, LLC & cauTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1).Fig 5: Identifying Caliper Mounting Bott Bushings And Boot Seals 8120067 Coutesy of CHRYSLER GROUP, LC 10. Push caliper mounting bolt bushings (2) out of the boot seals (3) and remove the boot seals from the caliper (1), 11, Remove caliper bleed screw. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > CLEANING > CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint ree towels or use low pressure compressed ait, & caution: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave @ residue that could damage the piston and seal,‘The piston is made from a phenolic resin (plastic material) and should be smooth and clean, ‘The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing QA caution: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > ASSEMBLY > ASSEMBLY Fig 4: Installing Piston Seals CCoutesy of CHRYSLER GROUP. LLCQ caution: Dirt oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid [°) note: Verity seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2) Fig 2: Installing Piston Into Bore Courtesy of CHRYSLER GROUP, LL 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4, Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place.Fig 3: Seating Dust Boot Coutesy of CHRYSLER GROUP, LLC 6. Seat dust boot in caliper (2) with Universal Driver Handle (special tool #0-4171, Driver Handle, Universal) (1) and Dust Boot Installer (special too! #8280, Installer, Dust Boot) (3). 7. Install the second piston and dust boot. 8. Install the boot seals into the caliper seal bores and center the seals in the bores. (°) Nore: DO NOT add grease to guide pins, pin bushings, housing shoe face or anchor bracket rails. Clean anchor bracket rails and housing shoe face with brake cleaner prior to assembly of new linings. 9. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing, 10. Install caliper bleed screw.EXCEPT SRT8 *) NOTE: Front brake caliper shown, rear calipers similar. *) NOTE: DO NOT add grease fo guide pins, pin bushings, housing shoe face or anchor bracket rails. Clean anchor bracket rails and housing shoe face with brake cleaner prior to assembly of new linings. Fig 1: Caliper, Banjo Bolt, Brake Hose & Guide Pins ‘Courtesy of CHRYSLER GROUP. LLC(°) NoTE: Brake caliper slide bolts (guide pins) (1) should be free from debris. 1, Position the brake caliperipads and tighten the brake caliper slide bolts (guide pins) (1) to: a. Front - 55 N.m (41 ff. Ibs.) b. Rear - 27.5 N.m(20 ft. Ibs.) 2. Install the caliper slide bolt dust shields. Q cauTion: Verify brake hose is not twisted or kinked before tightening banjo bolt 3. Install brake hose (3) to caliper (2) with new copper washers and tighten banjo bolt (4) to 30 Nim (23 ft. Ibs.)Fig 2: Brake Caliper Tension Clip Coutesy of CHRYSLER GROUP, LC 4. Install the brake caliper tension clip (1) 5. Remove the prop rod from the brake pedal 6. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. . Refer to STANDARD PROCEDURE 7. Install wheel and tire assembly. Refer to WHEELS, STANDARD PROCEDURE 8. Remove supports and lower vehicle. 9. Verify brake fluid level is correct. HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > INSTALLATION > FRONT - SRT8CAUTION: Always inspect brake pads before installing disc brake caliper and replace as necessary. (f) note: Views are typical. 1, Completely retract the caliper pistons back into the bores of the caliper. Use hand pressure or a C-clamp may also be used to retract the pistons, first placing a wood block or used brake pad (not to be reused) over the pistons before installing C-clamp to avoid damaging the piston. 2. If the brake pads need to be replaced, install in the caliper before installation. Refer to PADS ANDIOR SHOES, BRAKE, INSTALLATION 3. Slide the caliper with pads over the brake rotor and align with the knuckle Fig 1: Caliper Mounting Bolts, Banjo Bolt & Brake Hose 0S080965894. Install the caliper mounting bolts (1) and tighten to 200 N.m (148 ft. Ibs.) 5. Install the banjo bolt (3) attaching the brake hose (2) to the caliper. Install NEW washers on each side of the hose fitting as the banjo bolt is placed through the banjo fitting, Thread the banjo bolt (3) into the caliper and tighten to 30 N.m (22 ft. Ibs.) 6. Install the tire and wheel assembly. 7. Remove the supports and lower the vehicle 8, Remove the brake pedal holding tool. 9. Connect the battery negative cable to battery, 10. Remove the prop rod from the brake pedal 11, Bleed the area of repair for the brake system, If a proper pedal Is not felt during bleeding an area of repair then a base bleed system must be performed . Refer to STANDARD PROCEDURE HYDRAULIC/MECHANICAL > CALIPE! SRT8 DISC BRAKE > INSTALLATION > REAR - (f) note: Views are typical.Fig 1: Caliper, Brake Pads, Caliper Mounting Bolts, Banjo Bolts & Hose Fitting Courtesy of CHRYSLER GROUP LLC CAUTION: Always inspect brake pads before installing disc brake caliper and replace as necessary. 1. Completely retract the caliper pistons back into the bores of the caliper, Use hand pressure, or a C-clamp may also be used to retract pistons, first placing a wood block or used brake pad (not to be reused) over the piston before installing the C-clamp to avoid damaging the piston. 2. If installing new brake pads (5). Refer to PADS AND/OR SHOES, BRAKE, INSTALLATION .Fig 2: Rear Brake Caliper, Caliper Bolt, Banjo Bolt & Flexisble Brake Hose Coutesy of CHRYSLER GROUP, LC 3, Slide the caliper (4) with pads over the brake rotor and align with the knuckle. 4. Install the caliper mounting bolts (1) and tighten to 120 N.m (89 ft. Ibs.) 5. Install the banjo bolt (2) attaching the brake hose (3) to the caliper (4). Install NEW washers on each side of the hose fitting (3) as the banjo bolt is placed through the hose fitting (3), Thread the banjo bott (2) into the caliper (4) and tighten to 30 Num (22 ft. Ibs.) torque. 6. Install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE CAUTION: If NEW brake pads have been installed, keep in mind that braking effectiveness might be somewhat reduced during the first brake applications. 7. Remove the supports and lower the vehicle.9. Remove the prop rod from the brake pedal 10. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed . Refer to STANDARD PROCEDURE HYDRAULIC/MECHANICAL > FLUID > DESCRIPTION > BRAKE FLUID ‘The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only ‘Mopar brake fluid or an equivalent from a tightly sealed container. & caution: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid 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, ete. HYDRAULIC/MECHANICAL > FLUID > DESCRIPTION > BRAKE FLUID - EXPORT The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. If DOT 3 brake fluid is not available, brake fluid conforming to DOT 4 specifications may be used in its place. The fluids are compatible, but DOT 4 usage may require additional fluid maintenance. No other type of brake fluid is recommended or approved for usage in the vehicle brake system, Use only Mopar® Brake Fluid DOT 3 Motor Vehicle or equivalent froma tightly sealed container. & caution: Never use reclaimed brake fluid or fluid from an container which has been left open. An ‘open container of brake fluid will absorb moisture from the air and contaminate the fluid. Q caution:transmission fluid, power steering fluid, ete. HYDRAULIC/MECHANICAL > FLUID > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. ‘Swollen rubber parts indicate the presence of petroleum in the brake fluid To test for contarrination, put a small amount of drained brake fluid in clear glass jar. If fluid separates. into layers, there is mineral oil or other fluid contamination of the brake fluid If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. HYDRAULIC/MECHANICAL > FLUID > STANDARD PROCEDURE > STANDARD PROCEDURE - BRAKE FLUID LEVELFig 1: Identifying Power Brake Booster/Master Cylinder Components Courtesy of CHRYSLER GROUP LLC 1 -PUSH ROD 2- BOOSTER MOUNTING STUDS 3- POWER BRAKE BOOSTER 4- FLUID RESERVOIR 5 - MASTER CYLINDER 6 - FLUID LEVEL SENSOR, 7 = CHECK VALVE GROMMET “Aisvearse elesears Paes mmechinr pauilieerder peeceerieiv |AY cape peam beste abesicime five leuel Moment eleemee! eee‘The fluid fill level is indicated on the side of the master cylinder reservoir (4) ‘The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > DESCRIPTION > DESCRIPTION Fig 1: Identifying Power Brake Booster/Master Cylinder Components a1 afTabe Coutesy of CHRYSLER GROUP LLC 1=PUSH ROD 2- BOOSTER MOUNTING STUDS4- FLUID RESERVOIR 5 - MASTER CYLINDER 6 - FLUID LEVEL SENSOR, 7 - CHECK VALVE GROMMET The master cylinder body (5) is made of aluminum and contains a primary and secondary piston assembly. The cylinder body including the piston assemblies are not serviceable. If diagnosis indicates an internal problem with the cylinder body (5), it must be replaced as an assembly. The master cylinder has a removable reservoir (4) and fluid level indicator (6). The reservoir, reservoir grommets, reservoir cap and fluid level switch are the only replaceable parts on the master cylinder. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > OPERATION > OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. The master cylinder reservoir stores reserve brake fluid for the hydraulic brake circuits. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > DIAGNOSIS AND. TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER 1, Start the engine and check the booster vacuum hose connections. A hissing noise indicates a vacuum leak. Correct any vacuum leaks before proceeding. 2. Stop the engine and pump the brake pedal until all vacuum reserve in the booster is depleted. 3. Press and hold the brake pedal under light foot pressure. The pedal should hold firm, If the pedal falls away, there may be an external leak or the master cylinder is faulty (internal leakage). 4, Start the engine and note pedal action. It should fall away slightly under light foot pressure, then hold firm. If no pedal action is discernible, the power booster, vacuum supply or vacuum, check valve is faulty, proceed to the POWER BOOSTER VACUUM TEST 5. If the POWER BOOSTER VACUUM TEST passes, rebuild the booster vacuum reserve as follows: Release the brake pedal. Increase engine speed to 1500 RPM, close the throttle and immediately tum off the ignition to stop the engine. 6. Wait a minimum of 90 seconds and try brake action again. The booster should provide two or more vacuum assisted pedal applications. If the vacuum assist is not provided, the booster is. fatty HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > DIAGNOSIS AND1. Connect a vacuum gauge to the booster check valve with a short length of hose and T-ftting, 2, Start and run the engine at curb idle for one minute. 3. Observe the vacuum supply. If the vacuum supply is less that 12 inches HG (406 milibars), repair the vacuum supply. 4. Clamp the hose shut between the intake vacuum source and the check valve, 5. Stop the engine and observe the vacuum gauge: 6. If the vacuum drops more than one inch HG (33 millibars) within 15 seconds, the booster diaphragm or check valve is faulty. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER > POWER BOOSTER CHECK VALVE TEST 1, Remove the power booster check valve from the power booster. 2. Using a hand operated vacuum pump, apply 15-20 inches HG (508-677 millibars) vacuum at the booster side of the check valve. 3. The vacuum should hold steady. If the gauge on the pump indicates vacuum loss, the check valve is faulty and should be replaced. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > STANDARD PROCEDURE > STANDARD PROCEDURE - MASTER CYLINDER BLEEDINGCCoutesy of CHRYSLER GROUP LLC ‘Anew master cylinder should be bled before installation on the vehicle, Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 41. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4, Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > REMOVAL > REMOVAL & caution:sucking in any contamination as master cylinder is removed. This can be done simply by pumping brake pedal, with vehicle engine not running and the ignition OFF, until a firm feeling brake pedal is achieved. 1. With the engine not running and the ignition OFF, pump the brake pedal until a firm pedal is achieved (4-5 strokes), Fig 1: Connector, Hood Weather Strip, Extension, Fastener & Tab CCoutesy of CHRYSLER GROUP, LLC (2) Note: LHD shown, RHD similar. 2. Disconnect the connector (3) from the body and lft the hood weather strip (2) back enough for access to remove the cowl side extension (5), 3. Remove the fastener (1) that secures the cow! side extension (5) to the center cowl extension,Fig 2: Wire Connector & Brake Fluid Level Sensor Coutesy of CHRYSLER GROUP, LLC 5. Siphon the master cylinder (1). 6. Disconnect the wire connector (2) from the fluid level sensor (3).Fig 3: Brake Lines, Master Cylinder & Nuts 2836250 CCoutecy of CHRYSLER GROUP, LC 7. Disconnect the brake lines (4) at the master cylinder (1) 8, Remove the two master cylinder retaining nuts (3) and remove the master cylinder (1) from the booster HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > INSTALLATION > INSTALLATION [2] NOTE: Bleed new master cylinder on bench before installation,(8) Note: LHD shown, RHD similar. (8) Note: Wipe face of the brake booster clean where vacuum seal comes in contact when installed. [*) NoTE: Assure master cylinder seal is located on the rear of master cylinder before installing to booster.Fig 4: Brake Lines, Master Cylinder & Nuts CCoutesy of CHRYSLER GROUP LLC 1, Position the master cylinder (1) to the power brake booster, install the two NEW master cylinder retaining nuts (3) and tighten to 25 N.m (18 ft bs.) 2. Install the brake lines (4) at the master cylinder (1) and tighten to 19 N.m (168 in. Ibs.)Fig 2: Wire Connector & Brake Fluid Level Sensor Wns Coutesy of CHRYSLER GROUP, LLC 3. Connect the wire connector (2) to the fluid level sensor (3),Fig 3: Connector, Hood Weather Strip, Extension, Fastener & Tab = V7 ie Coutesy of CHRYSLER GROUP, LLC [) Nore: Make sure the tab (4) is snaps into place. 4, Position the cowl side extension (5) and install the cowl side extension to cowl extension fastener (1), 5. Install the hood weater strip (2) into position and attach the connector (3) to the body. 6. Fill and pressure bleed the brake system, Refer to STANDARD PROCEDURE . 7. Start engine and let idle for approximately 30 seconds, then turn off and wait about 1 minute. Fully stroke brake pedal to assure there are several strokes with assist prior to depletion of, vacuum. If not, check for missing seal between master cylinder and booster.PROCEDURE > STANDARD PROCEDURE - BRAKE PAD BURNISHING Q caution: After installing NEW brake pads, keep in mind that braking effectiveness might be somewhat reduced during the first brake applications. When NEW brake pads are installed on a vehicle, this procedure must be used to correctly burnish (seat) the brake linings to the brake rotor discs. 1. Accelerate the vehicle to a steady speed of about 40 mph (65 km/h). 2. Using light brake pedal pressure, slow the vehicle from 40 mph to 0 mph in approximately 6 seconds, 3. Accelerate back up to 40 mph for approximately one minute to allow the brakes to cool down. 4, Repeat this procedure 15 to 20 times to correctly seat the brake lining material. HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > REMOVAL > ALL EXCEPT SRT8 (*) Nore: Front brake caliper shown, rear calipers similar. 1. Drain @ small amount of fluid from the master cylinder brake reservoir with @ clean suction gun. 2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE 3. Remove the wheel and tire assembly.Fig 4: Brake Caliper Tension Clip Coutesy of CHRYSLER GROUP, LC 4, Bottom caliper pistons into the caliper. 5. Remove the brake caliper tension clip (1) by pressing rearward on the front of the clip (2) while puling the clip out (3) from the caliper.Fig 2: Brake Caliper, Adapter, Adapter Bolts & Guide Pins Coutesy of CHRYSLER GROUP, LLC 6. Remove the caliper slide dust bot shields andl loosen the brake caliper slide bots (guide pins) (2). & caution Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result Provide a suitable support to hang the caliper securely. 7. Remove the brake caliper (3) from the caliper adapter (4) and hang the brake caliper. 8. Remove the inboard and outboard brake pads. HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > REMOVAL > FRONT -*) NOTE: Views are typical Fig 1: Lower Brake Pad Support Pin, Caliper, Brake Pad Spring Clip, Upper Support Pin & Center Bolt Courtesy of CHRYSLER GROUP LLC 4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE 2, Remove the front tire and wheel assembly 3. Using a hammer and pin punch from the outboard end, tap the lower brake pad support pin (4) out of the caliper (1) 4. Remove the brake pad spring clip (3) out from under the upper support pin (2). 5. Using a hammer and pin punch from the outboard end, remove the upper brake pad support pin6. Remove the center bolt (6) and pin (5) from the caliper (1). Fig 2: Removing/installing Brake Pad CCoutesy of CHRYSLER GROUP, LLC Q cauTioN: When pushing pistons back into caliper bores, if hand pressure is not sufficient, use only a trim stick or other suitable soft too! to do so. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor or pads. 7. Using hand pressure, pull the pads back to seat the caliper pistons into the caliper bores if possible. If not possible, perform the following to do this correctly without damaging the caliper, pistons, dust boots or brake rotor disc. a. Place trim stick between the inboard brake pad and the outer edge of rotor. b. Using a trim stick, apply pressure against the inboard brake pad until both pistons are completely bottomed in bores of the inboard caliper half. Leave the trim stick in place to hold pistons in place.above step on the outboard pad and pistons. [] NOTE: Once brake pads are removed from caliper, inspect all four caliper pistons and dust boots for evidence of brake fluid leakage. Also inspect dust boots on all caliper pistons for any cuts, tears or heat cracks and brake pad supports (if equipped) for excess wear or damage. If caliper fails inspection, it should be replaced, 8. Remove the brake pads (1, 2) through the opening in the caliper (3). HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > REMOVAL > REAR - SRT8 [2] NOTE: Views are typical. 1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 2, Remove the tire and wheel assembly. 3. Using a hammer and pin punch on the outboard end, tap the upper brake pad support pin (1) out of the caliper (2). 4, Remove the brake pad spring clip (3) out from under the lower support pin (4) still in the caliper. 5. Using a pin punch and hammer, remove the lower brake pad supoort pin (4) in the same manner used on the upper support pin.Fig 1: Brake Pad Support Pins 28721 CCoutesy of CHRYSLER GROUP. LLC Q CAUTION: When pushing pistons back into caliper bores, if hand pressure is not sufficient, use only a trim stick or other suitable soft tool to do so. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor or pads. 6. Using hand pressure, pull the pads back to seat the caliper pistons into the bores if possible. If not possible, perform the following to do this correctly without damaging the caliper, pistons, dust boots or brake rotor disc. @. Place a trim stick between the inboard brake pad and the outer edge of rotor. b. Using a trim stick, apply pressure against the inboard brake pad until both pistons arec. Place a second trim stick between the outboard brake pad and rotor, then repeat above step on the outboard pad and pistons. Fig 2: Removingiinstalling Brake Pads 267218) Ccoutesy of CHRYSLER GROUP, LLC 7. Remove the inboard and outboard brake pads (2) through the opening in the caliper (1). 8. Once the brake pads are removed from the caliper (1), inspect all four caliper pistons and dust boots for evidence of brake fluid leakage. Also inspect the dust boots on all caliper pistons for any cuts, tears or heat cracks and brake pad supports (if equipped) for excess wear or damage. If the caliper fails inspection, it should be replaced. HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > INSPECTION > INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will beFig 1: Brake Pad Friction Material Thickness Measurement ® Courtesy of CHRYSLER GROUP LLC 1 - BRAKE SHOE ASSEMBLY FRICTION MATERIAL THICKNESS IS TO BE MEASURED AT THE THINNEST POINT. 2 BRAKE SHOE ASSEMBLY FRICTION MATERIAL 3- BRAKE SHOE ASSEMBLY BACKING PLATE ‘Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on @ brake pad lining (2) measured at its thinnest point measures one milimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. itis also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from.(°) NoTE: itis important to inspect both front and rear brake pads during the same inspection. HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > INSTALLATION > ALL. EXCEPT SRT8 ["] Nore: Front brake caliper shown, rear calipers similar. (°) NOTE: DO NOT add grease to guide pins, pin bushings, housing shoe face or anchor bracket rails. Clean anchor bracket rails and housing shoe face with brake cleaner prior assembly of new linings.Fig 1: Brake Caliper, Adapter, Adapter Bolts & Guide Pins courtesy SLER GROUP LLC | NOTE: Brake caliper slide bolts (guide pins) (1) should be free from debris, 1, Position the brake caliper/pads and tighten the brake caliper slide bolts (guide pins) (2) tor a. Front - 56 N.m (41 ff. Ibs.) b. Rear - 27.5 N.m(20 ft. Ibs.) 2. Install the caliper slide bolt dust shields.Fig 2: Brake Caliper Tension Clip Coutesy of CHRYSLER GROUP, LC 3. Install the brake caliper tension clip (1), 4. Install wheel and tire assembly. Refer to WHEELS, STANDARD PROCEDURE 5. Remove supports and lower vehicle. 6. Pump brake pedal until caliper pistons and brake pads are seated and a firm brake pedal is obtained. HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > INSTALLATION > FRONT - SRT8 *) NoTE: Views are typical.Fig 4: RemovinglInstalling Brake Pad 81778236) Coutesy of CHRYSLER GROUP LLC 1, Make sure all caliper pistons are fully seated (bottomed) in bores. (8) Nore: Brake pads need fo have the shims and cooper paste applied. Paste Is applied between the shim and the backing plate of the pads, and along the edges of the pads. 2, Slide the NEW inboard (2) and outboard brake pads (1) and shims into the opening of the disc brake caliper (3).Fig 2: Lower Brake Pad Support Pin, Caliper, Brake Pad Spring Clip, Upper Support Pin & Center Bolt Courtesy of CHRYSLER GROUP, LLC Install the pin (5) and center bolt and torque to 32.5 N.m (24 ft. Ibs.) From the inboard side, slide the upper brake pad support pin (2) through the caliper and upper holes in both brake pads. Make sure that the small end of the support pin (2) is in the hole in the outboard half of the caliper (1). Install the upper end of the brake pad spring clip (3) under the upper brake pad support pin (2). Press on the lower end of the spring clip (3) until it touches the brake rotor. Slide the lower brake pad support pin (4) through the caliper and lower holes in both brake pads in the same manner the upper pin was installed. Make sure the small end of the support pin (4) is in the hole in the outboard half of caliper (1). Release the spring clip (3) allowing it to engage the lower support pin (4). From the inboard side, seat the upper and lower support pins (2, 4) into the caliper (1) using a pin punch and hammer. Support pins must be driven into the caliper until the support pinsure spring clip (3) is centered in the opening of the caliper, correctly engaging the upper and lower support pins, and Is resting against both brake pads. 11. Install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE 12, Remove the supports and lower the vehicle. 13. Pump the brake pedal several times to set the pads to the caliper and brake rotor. 414. Check and adjust the brake fluid level in reservoir. Refer to FLUID, STANDARD PROCEDURE. [] NoTE: When NEW brake pads are installed, they must be bumished (seated) to the rotor. This must be done to ensure the proper performance of the replacement brake pads. 48, Road test the vehicle making several stops to wear off any foreign material on the brakes and to seat the brake pad linings. NEW brake pads need to be burnished properly. Refer to PADS ANDIOR SHOES, BRAKE, STANDARD PROCEDURE HYDRAULIC/MECHANICAL > PADS AND/OR SHOES, BRAKE > INSTALLATION > REAR - SRTS {") nore: Views are typical.Fig 4: RemovinglInstalling Brake Pads 267218) Courtesy of CHRYSLER GROUP. LLG 1, Make sure all caliper pistons are fully seated (bottomed) in the bores. (?) NoTE: Brake pads need to have cooper paste applied. Paste is applied along the edges of the pads. 2. Slide the NEW inboard and outboard brake pads (2) into the opening of the disc brake caliper (,Fig 2: Brake Pad Support Pins 28721 CCoutesy of CHRYSLER GROUP. LLC 3. From the inboard side, slide the lower brake pad support pin (4) through the caliper (2) and lower holes in both brake pads (5). Make sure that small end of the support pin (4) is in the hole in the outboard half of caliper. 4. Install the lower end of the brake pad spring clip (3) under the lower brake pad support pin (4). 5. Press on the upper end of the spring clip (3) unti it touches the brake rotor. 6. Slide the upper brake pad support pin (1) through the caliper (2) and upper holes in both brake pads (5) in the same manner the lower pin was installed, Make sure the small end of the support pin (1) is in the hole in the outboard half of caliper. 7. Release the spring clip allowing it to engage the upper support pinFig 3: Brake Components ag 267230) CCoutesy of CHRYSLER GROUP, LLC 8, From the inboard side, seat the upper and lower support pins (2) into the caliper (1) using a pin punch and hammer. Support pins must be driven into the caliper until the support pin retaining rings are locked into place. 9. Once the support pins are fully installed into the caliper, inspect the assembled caliper to make sure the spring clip (3) is centered in the opening of caliper, correctly engaging the upper and lower support pins (2), and is resting against both brake pads. 10. Install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE . 11, Remove the supports and lower the vehicle (°) Nore: When NEW brake pads are installed, they must be burnished (seated) to the rotor. This must be done to ensure the proper performance of the replacement brake pads. 42. Pump the brake pedal several times to set the pads to the caliper and brake rotor.HYDRAULIC/MECHANICAL > PEDAL(S), BRAKE AND/OR ACCELERATOR > DESCRIPTION > DESCRIPTION A suspended-type brake pedal is used, the pedal pivots on a shaft mounted in the pedal support bracket. The bracket is attached to the dash panel. ‘The brake pedal assembly and pedal pad are the only serviceable components. HYDRAULIC/MECHANICAL > PEDAL(S), BRAKE ANDIOR ACCELERATOR > REMOVAL > REMOVAL. Fig 1; Retainer Clip, Booster Push Rod, Brake Booster Mounting Nuts & Booster 27e7711 CCoutesy of CHRYSLER GROUP. LLCLHD shown, RAD similar. 4. Disconnect and isolate battery negative cable from battery post. 2, Remove the steering column opening cover. Refer to PANEL, INSTRUMENT 3. Remove the knee blocker air bag, if equipped. Refer to AIR BAG, KNEE BLOCKER, REMOVAL 4, Remove the stop lamp switch. NOTE: Do not discard the stop lamp switch as it can be adjusted and reinstalled. 5, Remove retainer clip (2) that holds booster push rod (4) to pedal pin. Discard retaining clip (2). Itis not to be reused. 6. Slide booster push rod (4) off brake pedal pin. 7. Remove the brake pedal sled upper nut (1) 8. Remove four power brake booster mounting nuts (3) 9. Remove the brake pedal assembly from the vehicle. HYDRAULIC/MECHANICAL > PEDAL(S), BRAKE ANDIOR ACCELERATOR > INSTALLATION > INSTALLATIONFig 4: Retainer Clip, Booster Push Rod, Brake Booster Mounting Nuts & Booster 2787711 Coutesy of CHRYSLER GROUP LLC [f) Nore: LHD shown, RHD similar. 1. Install the pedal assembly to the vehicle. 2. Install four power brake booster mounting nuts (3) and tighten to 20 N.m (15 ft Ibs.) 3. Install the upper brake pedal sled nut (1) and tighten to 20 N.m (16 ft. bs.) 4. Install booster push rod (4) on pedal pin and install a NEW retainer clip (2) on pedal pin. 5. Reinstall and adjust the stop lamp switch that was set aside for reuse.7. Install the steering column opening cover. Refer to PANEL, INSTRUMENT 8. Reconnect the negative battery cable. 9. Verify proper brake system operation. HYDRAULIC/MECHANICAL > PLATE, BRAKE BACKING > REMOVAL > REMOVAL Fig 1: Backing Plate Bolts & Backing Plate Assembly 2887406 CCouteny of CHRYSLER GROUP LLC [t) Note: The backing plate is only serviceable as an assembly with the park brakes attached.2, Remove wheel and tire assembly. (] NoTE: When the hub is removed from the knuckle, the bearing must be replaced. 3. Remove the hub/bearing, Refer to HUB AND BEARING, REMOVAL 4, Remove the backing plate bolts (2), and remove the backing plate assembly (1) from the knuckte. HYDRAULIC/MECHANICAL > PLATE, BRAKE BACKING > INSTALLATION > INSTALLATION Fig 1: Backing Plate Bolts & Backing Plate Assembly (2887406(°) NoTE: Anew backing plate assembly will have a plastic spacer to hold the park brake actuating lever in position to attach the brake cable. Do not remove the plastic spacer until the brake cable is attached to the lever. 1. Spread the shoes to fit over the stops and position the backing plate assembly (1) on the knuckle. 2. Install the backing plate bolts (2) and tighten to 13 N.m (116 in. Ibs.) [°) Nore: Remove the park brake lever spacer from this location (3) after attaching the brake cable, and before installing the rotor or adjusting the shoes. 3. Install the hub/bearing and knuckle. Refer to HUB AND BEARING, INSTALLATION. 4, Adjust brake shoes. Refer to SHOES, PARKING BRAKE, ADJUSTMENTS. 5. Install the wheel and tire assembly. Refer to WHEELS, STANDARD PROCEDURE 6. Remove the support and lower the vehicle. HYDRAULIC/MECHANICAL > RESERVOIR, BRAKE MASTER CYLINDER > REMOVAL > REMOVALFig 1: Brake Fluid Level Sensor Electrical Connector, Reservoir & Screw ~~ ad Cay RGROUP Lc 4, Remove reservoir cap and remove fluid with a clean suction gun. 2, Remove the electrical connector from the brake fluid level sensor (1). 3. Remove the reservoir retaining screw (3) 4, Carefully rock the reservoir (2) be cylinder. and fourth while pulling up to remove it from the master 5. Remove and transfer the brake fluid level switch. Refer to SWITCH, BRAKE FLUID LEVEL, REMOVAL 6. Remove and discard grommets from the cylinder body.Fig 1: Brake Fluid Level Sensor Electrical Connector, Reservoir & Screw ~~ ad Cay RGROUP Lc 4. Install the fluid level sensor (1) into the reservoir (2). CAUTION: Do not use tools fo install the o-rings. Tools may cut, or tear the o-rings. Install the o-rings using finger pressure only. 2. Lubricate new o-rings with clean brake fluid, CAUTION: Do not rock the reservoir during installation.3. Start reservoir (2) in o-rings then press the reservoir (2) straight down to seat the reservoir Into the cylinder o-rings. 4. Install the reservoir retaining screw (3). Install the wire connector to the brake fluid level sensor (1). 6. Fill master cylinder. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > FRONT > ROTOR MINIMUM THICKNESS Rotor minimum usable thickness is 30.5 mm (1.200 in.). Do not resurface a rotor if machining would cause thickness to fall below this limit. Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if worn below minimum thickness, or if refinishing would reduce thickness below the allowable minimum, HYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > FRONT > FRONT ROTOR THICKNESS VARIATIONFig 4: Measuring Rotor Thickness TAKE MINIMUM OF 6 MEASUREMENTS AROUND ROTOR J9405-103 Coutesy of CHRYSLER GROUP LLC 1- MICROMETER 2-ROTOR \Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness @ minimum of six points around the rotor face. Position the micrometer approximately 19 mm (3/4 in.) from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.012 mm (0.0006 in.) from point to point on the rotor. Refinish or replace the rotor if necessary. [8 Note: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to theFront rotors and hub/bearings are matched mounted for minimum lateral runout. Before removing the rotor, mark the rotor and hub/bearing to maintain original orientation. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > FRONT > FRONT ROTOR LATERAL RUNOUT Fig 4: Checking Rotor Runout And Thickness Variation J8905-68 Courtesy of CHRYSLER GROUP LLC DIAL INDICATOR Check rotor lateral runout whenever pedal pulsation, or rapid, uneven brake lining wear hes ocurred, The rotor must be securely clamped to the hub to ensure an accurate runout measurement. Secure the rotor with a minimum of 3 lug nuts and large diameter flat washers on each studHYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > REAR > ROTOR MINIMUM THICKNESS Minimum usable thickness of @ solid rear disc brake rotor is 12.5 mm (0.492 in.) and for a vented rear disc brake rotor is 20.5 mm (0.807 in.). The thickness specification is located on the center section of the rotor. Never resurface a rotor if machining would cause thickness to fall below this limit ‘Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if wom below minimum thickness, or if refinishing would reduce thickness below the allowable minimum. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > REAR > REAR ROTOR THICKNESS VARIATION 2) NOTE: Vented rotor shown, solid rotor similar.Fig 1: Measuring Rotor Thickness TAKE MINIMUM OF 6 MEASUREMENTS AROUND ROTOR J9405-103 Coutesy of CHRYSLER GROUP LLC Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at a minimum of six points around the rotor face. Position the micrometer approximately 19 mm (3/4 in.) from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.012 mm (0.0005 iin.) from point to point on the rotor. Refinish or replace the rotor if necessary. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > DIAGNOSIS AND TESTING > REAR > REAR ROTOR LATERAL RUNOUT Check rotor lateral runout whenever diagnosis indicates pedal pulsation and rapid, uneven brake lining wear.Use a dial indicator to check lateral runout. Maximum allowable lateral runout is 0.05 mm (0.0019 in.) HYDRAULIC/MECHANICAL > ROTOR, BRAKE > STANDARD PROCEDURE > STANDARD PROCEDURE - DISC BRAKE ROTOR MACHINING. *) NoTE: A hub mounted on-vehicle lathe is highly recommended. This type of lathe trues the rotor to the vehicles hub/bearing. The disc brake rotor can be machined if scored or worn. The on-vehicle lathe must machine both sides of the rotor simuttaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the on-vehicle lathe. Equipment capable of machining only one side at a time may produce @ tapered rotor This type of rotor machining is not recommended | NOTE: Proper wheel torque is also critical to help prevent any warping of the disc brake rotor. Q CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > REMOVAL > REMOVAL ] NOTE: Front rotor shown, rear rotor similar.Fig 1: Brake Caliper Tension Clip Courtesy of CHRYSLER GROUP LLC 4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE 2, Remove the wheel and tire assembly. 3. Bottom caliper pistons into the caliper. 4, Remove the brake caliper tension clip (1) by pressing rearward on the front of the clip (2) while pling the clip out (3) from the caliper.5. Remove the caliper slide dust btt shields and loosen the brake caliper slide bots (Quide pins) (2). & caution Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result Provide a suitable support to hang the caliper securely. 6. Remove the brake caliper (3) from the caliper adapter (4) and hang the brake caliper (3) 7. Remove the brake caliper adapter mounting bolts (1) and remove adapter (4) from the vehicle.Fig 3: Disc Brake Rotor Hub & O-Ring 265702) Coutesy of CHRYSLER GROUP, LLC 1-ROTOR 2- O-RING 8. If equipped, remove and discard the o-ring (2) securing the disc brake rotor (1) on the hub. 9. Remove the disc brake rotor from hubibeering. HYDRAULIC/MECHANICAL > ROTOR, BRAKE > INSTALLATION > INSTALLATION (") nove: Front rotor shown, rear rotor similar.Fig 4: Disc Brake Rotor Hub & O-Ring 285702! CCoutesy of CHRYSLER GROUP LLC 41. Install the rotor (1) on wheel studs.Fig 2: Brake Caliper, Adapter, Adapter Bolts & Guide Pins Coutesy of CHRYSLER GROUP, LC 2. Position the brake caliper adapter (4), install the brake caliper adapter mounting bolts (1) and tighten to: a. Front - 195 N.m (144 ft. Ibs.) b, Rear - 120 N.m (89 ft. Ibs.) NOTE: Caliper slide pins should be free from debris. 3. Position the brake caliper/pads and tighten the brake caliper slide bolts (guide pins) (2) to: a. Front - 56 N.m (41 ff. Ibs.) b, Rear - 27.5 N.m(20 ft. Ibs.)Fig 3: Brake Caliper Tension Clip Coutesy of CHRYSLER GROUP, LC 5, Install the brake caliper tension clip (1), 6. Install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE 7. Remove the supports and lower the vehicle 8. Pump brake pedal until caliper pistons and brake pads are seated and a firm brake pedal is obtained. HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > DESCRIPTION > DESCRIPTION Flexible rubber hose is used at the four brake calipers. Double walled steel tubing with double inverted flares are used on the brake lines.TESTING > DIAGNOSIS AND TESTING - BRAKE LINES/HOSES Flexible rubber hose is used at both front and rear brake calipers. Inspect the hoses whenever the brake systemis serviced, at every engine oil change, or whenever the vehicle is in for service Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions. Also check brake hose installation. Faulty installation can resutt in kinked, twisted hoses, or contact with the wheels and tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure. The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks, leaks, or other damage. Heavily corroded lines will eventually rust through causing leaks. In any case, corroded or damaged brake lines should be replaced. Factory replacement brake lines and hoses are recommended to ensure quality, correct length and superior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs. Also remember that right and left brake hoses are not interchangeable, Use new copper gaskets at all caliper connections. Be sure brake line connections are properly made (not cross threaded) and tightened to recommended torque. HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > STANDARD PROCEDURE > DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall stee! tube can be used for emergency repair when factory replacement parts are not readily available. Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare.Fig 4: Double Inverted Flaring CCoutesy of CHRYSLER GROUP LLC 1, Cut off damaged tube with Tubing Cutter. 2, Ream cut edges of tubing to ensure proper flare. 2. Install replacement tube nut on the tube. 4. Insert tube in flaring tool 5. Place gauge form over the end of the tube.7. Tighten the tool bar on the tube 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > REMOVAL > PRIMARY AND SECONDARY BRAKE TUBES [°) NoTE: LHD shown, RHD similar. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this Position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Siphon the master cylinder reservoir. 3. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL - 3.0L , BODY, AIR CLEANER, REMOVAL - 3.0L Turbo Diesel , BODY, AIR CLEANER, REMOVAL - 3.6L , BODY, AIR CLEANER, REMOVAL - 5.7L or BODY, AIR CLEANER, REMOVAL - 6.4LFig 1: Connector, Hood Weather Strip, Extension, Fastener & Tab = V7 ie Fe py Ks i 2839762 Coutesy of CHRYSLER GROUP, LLC 4. Disconnect the connector (3) from the body and lift the hood weather strip (2) back enough for access to remove the cowl side extension (5). 5. Remove the fastener (1) that secures the cow! side extension (5) to the center cowl extension, 6. Release the tab (4) that secures the cow side extension (5) and remove the extension.2774155) Coutosy of CHRYSLER GROUP, LLC 7. If necessary, remove the power steering reservoir retaining screw (1), hose routing clips, and position reservoir aside.Fig 3: Brake Lines, Master Cylinder & Nuts Coutesy of CHRYSLER GROUP, LLC 8, Remove the primary or secondary brake tude(s) (4) at the master cylinder (1).Fig 4: Hydraulic Control Unit (HCU), Primary & Secondary Brake Tubes, Chassis Lines & Antilock Brake System (ABS) Module Electrical Connector f' i ' WX 2841653 Courtesy of CHRYSLER GROUP, LL 9. Remove the primary or secondary brake tube(s) (2) at the HCU (1) 10. Remove the primary or secondary brake tube(s) from routing clip and from vehicle HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > REMOVAL > FLEXIBLE HOSE [2] NOTE: Front flexible brake hose shown, rear similar. 4. Install prop rod on the brake pedal to keep pressure on the brake system. Holding pedal in this,Fig 1: Wiring Routing Clip, Flexible Brake Hose, Banjo Bolt & Brake Hose Coutesy of CHRYSLER GROUP, LLC 2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 3. If removing rear flexible brake hose, remove the tire and wheel assembly 4. If equipped, disconnect the wheel speed sensor wiring routing clip (1) from the flexible brake hose (2), 5. Remove the banjo bolt (3) from the brake hose (2) and discard the washers,Fig 2: Solid Brake Line Fitting, Flexible Brake Hose & Retaining Clip 2841745 CCoutecy of CHRYSLER GROUP, LC 6. Remove the solid brake line fiting (1) from the flexible brake hose (2). 7. Remove the retaining clip (3) and remove the flexible brake hose (2) from the vehicle. HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > INSTALLATION > PRIMARY AND SECONDARY BRAKE TUBES [*) Nore: LHD shown, RHD similar.Fig 4: Hydraulic Control Unit (HCU), Primary & Secondary Brake Tubes, Chassis Lines & Antilock Brake System (ABS) Module Electrical Connector Coutesy of CHRYSLER GROUP LLC 4. Position the primary or secondary brake tube(s) (2) in the vehicle and attach to the routing clip. 2. Connect the primary or secondary brake tube(s) (2) at the HCU (1) and tighten to 19 N.m (168 in. bs.)Fig 2: Brake Lines, Master Cylinder & Nuts Coutesy of CHRYSLER GROUP, LLC 3. Connect the primary or secondary brake tube(s) (4) at the master cylinder (1) and tighten to 19 Nim (168 in. Ibs.)2774155) Coutosy of CHRYSLER GROUP, LLC 4. If removed, route the power steering hoses and reservoir, install the routing clips, install the retaining bolt and tighten to 20 N.m (15 ft. Ibs.)Fig 4: Connector, Hood Weather Strip, Extension, Fastener & Tab Coutesy of CHRYSLER GROUP, LLC (5) Nore: Make sure the tab (4) snaps into place. Position the cow! side extension (5) and install the cowl side extension to cowl extension, fastener (1), Install the hood weather strip (2) into position and attach the connector (3) to the body. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION - 3.0L , BODY, AIR CLEANER, INSTALLATION - 3.0L Turbo Diesel , BODY, AIR CLEANER, INSTALLATION - 3.6L. , BODY, AIR CLEANER, INSTALLATION - 5.7L or BODY, AIR CLEANER, INSTALLATION - 6.4L Remove the prop rod from the brake pedal.HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > INSTALLATION > FLEXIBLE HOSE ({) NoTE: Front flexible brake hose shown, rear similar. Fig 1: Solid Brake Line Fitting, Flexible Brake Hose & Retaining Clip 2841745 (Courtesy cf CHRYSLER GROUP, LLC 1, Position the flexible brake hose (2) through the bracket and install the retaining clip (3) 2, Tighten the solid brake line fitting (1) to 19 N.m (168 in, Ibs.)..Fig 2: Wiring Routing Clip, Flexible Brake Hose, Banjo Bolt & Brake Hose fa 2841710 CCoutecy of CHRYSLER GROUP, LC 3. Install new washers , and the banjo bolt through the line and into the caliper. Tighten the banjo bolt to 30 N.m (22 ft. Ibs.) 4. If equipped, connect the wheel speed sensor wiring routing clip (1) to the flexible brake hose (2) 5. If installing the rear flexible brake hose, install the tire and wheel assembly. Refer to WHEELS, STANDARD PROCEDURE 6. Remove the supports and lower the vehicle 7. Remove the prop rod from the brake pedal 8. Bleed the area of repair for the brake system, if a proper pedal Is not felt during bleeding an area of repair then a base bleed system must be performed . Refer to STANDARD PROCEDURE‘The parking brakes operated by a automatic tensioner mechanism built into the foot lever and cable system. The front cable is connected to the foot lever and the equalizer. The rear cables attached to the equalizer and the parking brake shoe actuator. A set of drum type brake shoes are used for parking brakes. The shoes are mounted to the rear disc brake adaptor. The parking brake drum is integrated into the rear disc brake rotor. Parking brake cable adjustment is controlled by an automatic tensioner mechanism. The oniy adjustment if necessary is to the parking brake shoes if the linings are worn, PARKING BRAKE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - PARKING BRAKE SYSTEM (8) note: Parking brake adjustment is controlled by an automatic cable tensioner and does not require adjustment The only adjustment that may be necessary would be to the park brake shoes if they are worn. ‘The parking brake switch is in circuit with the red warning lamp in the dash. The switch will cause the lamp to illuminate only when the parking brakes are applied. ifthe lamp remains on after parking brake release, the switch or wires are faulty. Ifthe red lamp comes on a fault has occurred in the front or rear brake hydraulic system. If the red warning lamp and yellow warning lamp come on, the electronic brake distribution may be at fait In most cases, the actual cause of an improperly functioning parking brake (too loose/too tight/wan't hold), can be traced to a parking brake component. {") Note: The leading cause of improper parking brake operation, is excessive clearance between the parking brake shoes and the shoe braking surface. Excessive clearance is a result of lining and/or drum wear, drum surface machined oversize. Excessive parking brake lever travel (sometimes described as a loose lever or too loose condition), is the result of worn brake shoes, improper brake shoe adjustment, or improperly assembled brake parts. too loose condition can also be caused by inoperative or improperly assembled parking brake shoe parts. condition where the parking brakes do not hold, will most probably be due to a wheel brake component. Items to look for when diagnosina a parkina brake problem. are:* Drum surface (in rear rotor) machined oversize ‘= Front cable not secured to lever « Rear cable not attached to actuator * Rear cable seized + Parking brake lever not seated * Parking brake lever bind PARKING BRAKE > STANDARD PROCEDURE > STANDARD PROCEDURE - PARKING BRAKE SYSTEM LOCKOUT > MANUAL LOCKOUT Fig 1: Parking Brake Cable, Gears & Tie Strap 2668988) CCoutesy cf CHRYSLER GROUP, LLC2. Pull back on the parking brake cable (3) between the cable housing attachment and the cable attachment at the parking brake lever bracket assembly all the way to the stop. 3, From in front of the parking brake lever assembly, insert the end of a 204 mm (8 in.) tie strap (2) between the gears (1. 4) and slowly release the tension on the parking brake cable (3). The tie strap (3) should pul in slightly and hold the gears (1, 4) in place, making access to remove and install the parking brake cable at the back of the brake lever assembly. (°) nore: When the parking brake lever assembly is installed with the front parking brake cable AND the cable housing properly connected to the lever assembly the lockout can be removed. 4, Remove the lockout as follows: 1. Pullback on the parking brake cable (3) between the cable housing attachment and the ‘cable attachment at the parking brake lever bracket assembly all the way to the stop. 2, Remove the tie strap (2) from between the gears (1, 4) and slowly release the tension on the parking brake cable (3). 5. Press the parking brake foot lever once and verify the parking brake assembly sets. 6. Press the parking brake foot lever again and verify the parking brake assembly releases. PARKING BRAKE > STANDARD PROCEDURE > STANDARD PROCEDURE - PARKING BRAKE SYSTEM LOCKOUT > FACTORY LOCKOUT (NEW ASSEMBLY)Fig 1: Lockout Hoop, Hole & Lockout Hoop ~ 2889034 CCoutesy of CHRYSLER GROUP LLC *] NOTE: When the parking brake lever assembly is installed with the front parking brake cable AND the cable housing properly connected to the lever assembly the lockout can be removed. 1, Remove the factory lockout as follows: 4, Squeeze the lockout hoop (3) together and twist the back side out to remove from the hole (2) in the parking brake lever. 2. Pull the bottom of the lockout hoop (1) out and twist upward to remove the lockout hoop. from parking brake assembly. 9 Press the parking brake foot lever once and verify the parking brake assembly sets.PARKING BRAKE > CABLE, PARKING BRAKE > REMOVAL > FRONT - LHD Fig 1; Rear Parking Brake Cables, Equalizer & Body Retaining Nut Ne 7 % 2791570 CCoutesy of CHRYSLER GROUP LLC 1, Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE 2, Disconnect the right reer and left rear parking brake cables (2, 5) from the equalizer (1). 3. Remove the cable to body retaining nut (3) and clip from the stud. 4, Remove the supports and lower the vehicleFig 2: Cable Housing Tabs, Cable Housing & Bracket Assembly 2692961 CCoutecy of CHRYSLER GROUP, LC 5. Remove the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING, REMOVAL 6. Remove the left footwell load floor. Refer to LOAD FLOOR, FOOTWELL, REMOVAL 7. Remove the left rear seat. Refer to SEAT, REAR, REMOVAL . 8. Lockout the parking brake lever assembly. Refer to PARKING BRAKE, STANDARD PROCEDURE 9. Depress the cable housing tabs (3) and remove the cable housing (2) from the bracket assembly (1).Fig 3: Cable, Bracket Assembly & Cable End } 2892346 Coutesy of CHRYSLER GROUP, LLC 10. Pull the cable (2) up to align with the slot in the bracket assembly (3) and remove the cable end (1) from the bracket assembly (3).Fig 4: Retaining Studs 2791583) Coutosy of CHRYSLER GROUP, LLC 11, Remove the wiring hamess from the body retaining studs (2) as necessary. 412, Remove the front parking brake cable to body retaining nuts (2) and clips from the studs. 13. Disengage the arommet, pull the cable through the floor and remove the cable from the vehicle. PARKING BRAKE > CABLE, PARKING BRAKE > REMOVAL > FRONT - RHDFig 1: Rear Parking Brake Cables, Equalizer & Body Retaining Nut 2791570 Coutesy of CHRYSLER GROUP LLC [") nore: Lefthand drive shown, right hand drive similar. 1, Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 2. Disconnect the right rear and left rear parking brake cables (2, 5) from the equalizer (1). 3. Remove the cable to body retaining nut (3) and clip from the stud. 4, Remove the supports and lower the vehicleFig 2: Parking Brake Cable, Retaining Studs & Nuts Coutosy of CHRYSLER GROUP, LLC 5. Remove the right footwell load floor. Refer to LOAD FLOOR, FOOTWELL, REMOVAL 6. Remove the right rear seat. Refer to SEAT, REAR, REMOVAL 7. Pull the carpet back to gain access to the front parking brake cable (1), 8. Remove the wiring harness from the body retaining studs (2) as necessary. 9. Remove the front parking brake cable to body retaining nuts (2) and clips from the studs.Fig 3: Cable Housing Tabs, Cable Housing & Bracket Assembly Coutesy of CHRYSLER GROUP, LLC [) Nore: Left hand drive shown, right hand drive similar. 10. Lockout the parking brake lever assembly. Refer to PARKING BRAKE, STANDARD PROCEDURE 11, Depress the cable housing tabs (3) and remove the cable housing (2) from the bracket assembly (1).Fig 4: Cable, Bracket Assembly & Cable End CCoutecy of CHRYSLER GROUP, LC (5) Nore: Left hand drive shown, right hand drive similar 12, Pull the cable (2) up to align with the slot in the bracket assembly (3) and remove the cable end (1) from the bracket assembly (3). 413, Disengage the grommet, pull the cable through the floor and remove the cable from the vehicle, PARKING BRAKE > CABLE, PARKING BRAKE > REMOVAL > REARFig 1: Cable Retaining Bracket, Cable Housing & Equalizer Coutesy of CHRYSLER GROUP LLC 1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE . 2. Remove the parking brake shoes. Refer to SHOES, PARKING BRAKE, REMOVAL 3. Disconnect the brake cable end from the equalizer (3) 4. Depress the tabs on the cable housing (2) and pull through the cable retaining bracket (1).Coutosy of CHRYSLER GROUP, LLC 5. Remove the parking brake cable (1) from the retaining bracket (2) 6. Remove the tie straps and clips as necessary.Fig 3: Rear Park Brake Cable Remover & Cable 3109037) CCoutecy of CHRYSLER GROUP, LC (5) Nore: it may be necessary to slightly move or twist the cable release tool to disengage both retaining clips. 7. Using Rear Park Brake Gable Remover - (special tool #10301, Remover, Rear Park Brake Cable) (2), insert the tool over the park brake cable end and press in to release the retaining clips, then pull the cable (1) out of the knuckle from the back. PARKING BRAKE > CABLE, PARKING BRAKE > INSTALLATION > FRONT - LHDFig 1: Bolts & Clip & 2790356 CCoutesy of CHRYSLER GROUP LLCFig 2: Cable, Bracket Assembly & Cable End wA y 2892346 CCoutesy of CHRYSLER GROUP LLC 1. Install the front cable end (1) into the brake lever assembly (3).Fig 3: Cable Housing Tabs, Cable Housing & Bracket Assembly in ho Coutesy of CHRYSLER GROUP, LLC 2. Install the front cable housing (3) to the bracket (1).Fig 4: Retaining Studs Coutosy of CHRYSLER GROUP, LLC 3. Route the cable (1) along and through the floor, and seat the grommet so that itis sealed 4. Install the front parking brake cable to body clips and retaining nuts (2) to the studs and tighten to8Nm(71 in. Ib). 5. Install the wiring harness on the body retaining studs (2) as necessary. 6. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .Fig 5: Rear Parking Brake Cables, Equalizer & Body Retaining Nut ? a of 2791570 Coutosy of CHRYSLER GROUP, LLC 7. Connect the right rear and left rear parking brake cables (2, ) to the equalizer (1). 8. Install the cable to body clip and retaining nut (3) to the stud and tighten to 8 N.m (74 in. Ib.) 9. Remove the supports and lower the vehicle. 40. Remove the lockout of the parking brake assembly. Refer to PARKING BRAKE, STANDARD. PROCEDURE 11. Install the left footwell load floor. Refer to LOAD FLOOR, FOOTWELL, INSTALLATION. 12. Install the right rear seat. Refer to SEAT, REAR, INSTALLATION 13. Install the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING, INSTALLATION PARKING BRAKE > CABLE, PARKING BRAKE > INSTALLATION > FRONT - RHD