w BRAKES BRAKES ‘TABLE OF CONTENTS BRAKES - BASE pee 1 BRAKES - ABS. BRAKES - BASE ‘TABLE OF CONTENTS BRAKES - BASE DESCRIPTION - BRAKE SYSTEM DESCRIPTION - SERVICE WARNINGS & CAUTIONS DIAGNOSIS ANO TESTING | BASE BRAKE systen STANDARD PROGEDURE ‘STANDARD PROCEDURE - MANUAL STANDARD PROCEDURE - PRESSURE BLEEDING. TBRAKE COMPONENTS TORQUE CHART SPECIAL TOOLS BASE BRAKES: DESCRIPTION OPERATION AND HOSES STANDARD PROGEDLRE ‘STANDARD PROCEDURE - BRAKE TUBE FLARING INVERTED FLARING. STANDARD PROCEDURE - iSO FLARING DISC BRAKE CALIPERS DESCRIPTION ‘OPERATION REMOVAL REMOVAL - FRONT DISASSEMBLY ‘CLEANING. INSPECTION pee 2 ° ° 0 0 8 3 INSTALLATION INSTALLATION - REAR BRAKE PADSISHOES. REMOVAL REMOVAL - FRONT PADS REMOVAL -ORUM BRAKE SHOES REMOVAL -REAR DISC BRAKE PADS INSTALLATION INSTALLATION - DRUM BRAKE SHOES INSTALLATION - REAR DISC BRAKE PAOS DESCRIPTION OPERATION DIAGNOSIS ANG TESTING - BRAKE DRUM RUNOUT MACHINING CLEANING PADUUSTMENTS - REAR GRU BRAKE FLU [DIAGNOSIS ANO TESTING - BRAKE FLUIO (CONTAMINATION Level SPECIFICATIONS BRAKE FLUID FLUID RESERVOIR REMOVAL INSTALLATION MASTER CYLINDER OPERATION DIAGNOSIS ANG TESTING - MASTER (CYUNDERIPOWER BOOSTER 5-1 a 6 u 6 1 25-2 BRAKES - BASE 1 STANDARD PROCEDURE - MASTER INSTALLATION - REAR, 2 (CYLNOER BLEEDING 24 WHEEL CYLINDERS. REMOVAL 26 “REMOVAL 2 INSTALLATION 25 isassemsiy 2 PEDAL CLEANING 2 DESCRIPTION 25 INSPECTION 2 ‘OPERATION 25 ASSEMBLY 3 REMOVAL 28 _ INSTALLATION 3 INSTALLATION ‘26 SUPPORT PLATE POWER BRAKE BOOSTER REMOVAL. 2 DESCRIPTION 25 _ INSTALLATION = INSTALLATION 28 OPERATION 7 ‘COMBINATION VALVE DIAGNOSIS ANO TESTING : PARKING ‘OPERATION 28 SHOES: DIAGNOSIS ANO TESTING | CONRINATION DESCRIPTION Po VALVE 29 OPERATION 35 REMOVAL 2 REMOVAL 3 INSTALLATION 23 CLEANING- REAR ORUM WHAT BRAKE "36 ROTORS INSPECTION REAR ORUM IN HAT RAKE 36 DIAGNOSIS ANO TESTING INSTALLATION cS ROTOR 20 “ADJUSTMENT - REAR ORUM IN HAT PARK. DIAGNOSIS ANO TESTING - BRAKE ORL BRAKE (ROTOR REMOVED) 7 STANDARD PROCEDURE ‘CABLES STANDARD PROCEDURE - DISC ROTOR REMOVAL MACHINING. 31 REMOVAL - RUM BRAKES 2 STANDARD PROCEDURE - BRAKE DRUM REMOVAL DISC BRAKES. 38 REMOVAL INSTALLATION - DRUM BRAKES. 40 REMOVAL - FRONT 31 INSTALLATION - DISC BRAKES 0 INSTALLATION INSTALLATION - FRONT 2 BRAKES - BASE DESCRIPTION DESCRIPTION - BRAKE SYSTEM wer anit font dine ened rear deur bees are standard equipment, Dis brake components consist, sng pt arson ena tr. Rear "Tho parking brake mechanism Is lever an cable operated. The cables are attached to Tevers on the ear drum brake secondary. shoes. The parking brakes ae operated by a hand lever ‘dual dlaptragm vacium paver brake bosster ‘hum master efinder with plas reservoir, ‘All meets are equipped seth combination valve stand fined rate rear proportioning vale Fectory brake lining on all models consists of on ‘enyante base material combaned with metallic part ts. The orginal equipment linings da fot containw BRAKES - BASE (Continued) DESCRIPTION - SERVICE WARNINGS & ‘CAUTIONS, TAIN ASRESTOS FIBERS FROM PRODUCTION OR [AFTERMARKET LININGS, BREATHING EXCESSIVE CONCENTRATIONS OF ASDESTOS FIBERS. CAN BRAKE’ PARTS WITH COMPRESSED AIR OR GY DRY BRUSHING. USE A VACUUM CLEANER SPE- [ASBESTOS FIBERS FROM BRAKE COMPONENTS, Tr A SUITABLE VACUUM CLEANER IS NOT AVAIL: ABLE, CLEANING SHOULD BE DONE WITH A WATER DAMPENED CLOTH. 00 NOT SAND, OR IS DESIGNED TO CONTAIN THE DUST RESIDUE DISPOSE OF ALL RESIOUE CONTANING ASBES- ‘TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- ERS, FOLLOW PRACTICES PRESCRISED BY THE OCCUPATIONAL SAFETY AND HEALTH. ADMINIS: ‘TRATION AND THE ENVIRONMENTAL PROTECTION AGENCY FOR THE HANDLING, PROCESSING, AND DISPOSITION OF OUST OR DEBRIS THAT MAY ‘CONTAIN ASBESTOS FIBERS. ‘CAUTION: Never use gasoline, Kerosene, alcohol, motor ol, wanamission ful, oF any luld containing Inineral ol to clean the system components, These ftuids damage rubber cups aod seals. Use ony {reah beak ld or Mopar brake cleaner to clean ot ‘lush brake systom components. These are the ony ‘leaning materiale recommended. H system conta: ination ts suspected, check the Mud for dit dscol- ‘raion, or separation into distinct layers. Also ‘check the reservoir cap seal for distortion. Orain ‘and flush the system wits new brake uid If con- {tonination is suspected. ‘CAUTION: Use Mopar brake fud, or an equivalent ‘quality fld moeting SAEIDOT standards J1703 a DOT 3. Brake fd must be clean and fre of con ‘only to ensure proper antlock component operat tion ‘CAUTION: Use Mopar multimilage or high temper- ‘ature presse to lubricate caliper slide surfaces, ‘rum brake pivot pins, and shoe contact polnts on the Backing plates. Uso mult-milaage grace or CE BRAKES - BASE 5-3 {61 oF Dow 11 silicone grease on caliper slide pins to ensure proper operation, DIAGNOSIS AND TESTING - BASE BRAKE ‘SYSTEM Base rake components consi ofthe brake shoes calipers, whee eindes, broke uns, rotors, breke Ties, ester evlleder, booster, ond parking brake tem is related to a sechanica,hydrau, orvosuum cperated component The rt dlagrots sep s the preliminary check PRELIMINARY BRAKE CHECK (U)Cheek condition of ties and wheels, Damaged wheels and worn, damaged, or undernfated res Sine to arab. (2) Ircompleint was based on noise when braking cinck susperstn components. foun fant hd rear sf vehic ad Haten for mone thet might be coed by loose. urn or damaged suspension oF steering, ‘ponent (3) Inspect brake Maid evel and condition. Note Secrease in proportion to normal lining wear Also ote that brake fuld tends to darken over the, (al I uid level is abnormally la. laok for ev: cence ks cies wns take {b)It Mu appears eomaminste drain out 3 sample, System vil have to be flushed Hf Mit is ‘Separated Ino layers. or contains substance (ther than brake ful The system seals and fap ‘will alo have to be replaced alter Oushing. Use ‘dean broke fd to Mush the system, acne parang rake epettion Wey we tote if vehicle was being operated with parking, brake partly apple {51 Check brake pedol peradon. Verify that pedel locks tee play. check peal and power booster or ling loose” o for bind eondiion Dy not red est 16] Mremnponents checked appear OK, read tet the vehicle ROAD TESTING (0) AF camplaint inolved tow brake pedal. pump pedal anette i comes Bl up 10 nal Deg5-4 BRAKES - BASE BRAKES - BASE (Continued) (2) Check broke pedal response with transmission ln Neutral and engine running. Pedal should remain (3) During road test, make normal and fim brake ‘tps ia 25440 mph eonge. Nate Toulty brake opera tion sich as lw pel. hard pedal, peda pls Won pall gra, drag mau te ‘PEDAL FALLS AWAY ‘A brake pedal that falls away under steady font pressure is generally te eeslt of @ Syste leak The Fea point coud be at s brake line, ft. se, oF Cliperiheet cylinder, Interna leakage nthe master (Glider caused by warn wr danaged ston copa, tay aso e the problem cause leakage Is severe, Mid will be evident at oF leakage in the master einder mey not be piysialy evident. Low Peon Ka tw pedal i experienced, pump the pedal sv rotors, or drunie are the mest likely causen ‘SPONGY PEDAL ‘A spongy’ pedal fs most often caused by aie in the system However, thin brake drums or substandard ate lines and hoses cam alsa cause spongy pe ‘The prope course of action fo bleed the system. oF replace thin drams and suspect quality brake lines ‘hard pcal or high pedal effort may be due to lining thats water soaked, crotaninsted, glazed, cr haa worn. The power booster of ebedk valve could sls be fay Pedal pulsation iy caused by components that are laos. or beyond tolerance Tits “The primary tause of pusston are dise brake rotors with excessive lateral runout or thickness ar ftlon, or aut of round brake drums. Other causes re NOTE: Some [ABS aetvation ed pulsation may be felt during BRAKE DRAG Brake drag. cears when the ning tn constant ‘contact with the rotor or drum Drag ean occur atone ‘wheel all wheels, fronts any. or rears ony, 1 Drag is product of Incomplete brake shoe release, Drag on be minor or severe enough to overheat the Minar dag wll srually couse sight sueace char ring af the Unig. Ie ean also generate ard spa in ea. in wat enuen the retira, deur, heck rd 5 are lle warm Cathe touch afer the vlc s stopped ‘Severe drag can char the brake tng all the way iwough Tecan alo distor and score Tors ad “rus to the pont of eeplacement. The wheel, res fond brake components will be extremely hat. In Seren te ing ay goat nde Possible causes for brake dag canton ar 4 Seted oF Improperly adjusted parking. broke Lansehvorn whee! beating seed caliper or wheel «inde piston. + Caliper binding on corroded bushings oF rusted slide surfaces { Deum ‘brake shoes binding on wordamaged support laws. iti aseembled components Tr brake drag occur at all wheel, the problem may be related toa blocked master elinder return Port, o Faulty power buostor (binds does nat release ‘BRAKE FADE Brake fade is usually 2 product af overheating caused by brake drag. However, brake overeating land resuiung ade ca alo be caused by viding the brake pedal: making repeated high decsleraton stops Iva short ime span, or constane braking om steep ‘mountain ads, Refer wo he Brake Brag information, in this ection for ceases, ‘eaKE PULL Possble causes for font brake pull condone: + Contaminated nny In one eager: Binding eliper: Lae alien Rast adaptercalper side soefaces Innproper brake oes Damaged sae A worn, damaged wheel bearing or suspension component are further causes af pull A damaged Front tire (onased ply separate cal ene pul “A common and frequently nisdlagnosed pull cand tion is whore direction of pull changes after few ops, The cause a combination of brake drag fl Toned by Tale atone of the beake wnsw BRAKES - BASE (Continued) AS the dragging brake overeets, efficency 5 50 reduced that fode occurs, Since the oppolte brake togpied. This causes, pull to sitdh diecion in favor of the normally fanctioning rake ui. pull conlinn concerns ake coal daw, Rernember that pull will return to the original cect af the ‘ragging brake unit allowed to cool down (ad ts tot seriously damaged) REAR BRAKE GRAB OR PULL Rear grab ar pull fs usualy caused by improperly ‘edjustd or Sein parking bake cables, contami hated lining. bent or ining shoes and spore pt er improper” ase cnn Ths volved, However, when "both rear, wheels are ‘affected, the master Glinder or proportioning valve ‘ul ea fe ‘BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP lining. the ining is only wet. it ca be died by driving with the brakes very lightly applied for a tlle oF two, However ifthe lng both scaked nd te neceeary. ‘RAKE SQUEAKSQUEAL Brake squeak of squesl may be due to Inings that ace wet ee contaminated with race Tl, reese, oF {i Chased Thangs and rotors sith hard Spots can ‘So contribute te agueak, Dirt sal fre materi ‘beaded in the brake ing wl so ase squeal TX tey ld sora or qual equnty a sgn af severely worn Brake ling TE -the lining has worn though tothe broke shoes in spots, meta-to neal Comet acu Ire candi alowed (9 ent BRAKES - BASE 5-5 rotors end drums can become so scored that replace BRAKE CHATTER Brake chatter is wally caused by loose or warn ‘amponeris, or glazedurne Ung. Rocrs with hard Spots can also contribute to chater. Additonal causes of chater are out of bleranee ror, brake ining not ‘and comaminated brake Bing “HUMP NSE “Thunping or cunk noses during broking are fe quently not caused by brake components tn many Soci. suspension, or engine cmponents: However Calipers tt bind onthe aie surfaces can generate 2 'imp or chm pis Tn addin, worm noe ade npopry med er ‘BeaKE unas conravawerioN Brake lining contamination fs mostly a pradct of lang cipro whl ine wr we Contaminated lining should be repoced to void fur ther brake problems Some condiens attributed to broke components ‘dame wheel can cause shudder. vibration and pull A'worn or damaged tire can also cause pull, “Sey mn ith rye ce Feanvers traction. Flaspoted ies can cause vibe tion and generate shudder during breke operation, A ‘ct or py separation cat eause pull aed vibe,5-6 BRAKES - BASE BRAKES - BASE (Continued) STANDARD PROCEDURE ‘STANDARD PROCEDURE - MANUAL BLEEDING ‘Use Mopar brake fi or an equivalent. qualty Niwa meeting SAE J1703 Fond DOT 3 standards nly Use fra cle Ma from a sealed container a (0) Remove reserve filer caps and fl eeseevois (2) Ir calipers whe! cylinders were suet ‘Then cle each bleed screw ae Mid starts to drip fram Top off master ryder reservoir once: mace telore paced. (3) Attach oor end of bleed Hose to bled screw ‘and sett opposte end in glass container parelly ed with brake Mud (Fig. I) Be sure end of bleed hose Is inersed In Mu 1 Fr ee bleeder tank with recommended Makan ‘urge oe ram the tank ins before bleedin Do not psu bled witha procr master yin er adapter The wrong aaper cs lead 10 eskage ‘lawn air back ita sytem. Use adapir paved ‘sith the lpm ex Aare 6921 Fig. 1 Bleed Hose Setp SPECIFICATIONS BRAKE COMPONENTS ‘SPECIFICATIONS, [Disc Brake Catper | Siang Type Disc Bake Rotor Venta fre Fron Diee Brake Rotor Sale ype ise rake Rotor Taax sare mm Diameter assay Disc Brake Rotor WaSx Tm TT xOaTE Diameter in Rear ise rake Rotor ax Runout ersltee O12 mm (0005 in) Fron Disc Brake Rotor Tax, Rona os 402 mm (2008 est 2890518 [ac rake Rotor Tax, Therese Varaton erties 0.013 mm (20005 mn), (@) Open up bled, then havea helper pres dona te rake petal Once the pedal is down dose the Moder. Repeat ceding wit Nut stra sear and STANDARD PROCEDURE - PRESSURE BLEEDING Use Mops brake Mui or an equivalent quality Niwa meeting SAE J1703-F end DOT $ stendards ‘nly Use fresh clea Ma from 4 sled container a using pressure eqlpment Do not exceed Ue tank man facturers prose rvommenatiens. Cenerally anh pressire of [520 ps slike fr losin Sos ots mm (20007 mn) eat Disc Bake Rotor Wn Thess vensltee 227mm (08857 Fron Diee rake Rotor Tin Thenees Sts 1.00 (0438) race Dram TEEXESS mw Diameter ind Brave Booster Tandem Dap pew BRAKES - BASE (Continued) BRAKES - BASE 5-7 ‘TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION im Fob tbe ‘Supoert Bot a Brake Boorer a a = Mounting Nuts Waster Cyinaor 7 7 = Movatng Mute Tiasir Cyngor 7 7 {rake Lines Tambnation Vane a 5 = Movnting Wits Tompration Vane 7 7 7 Brake Lines Caer 7 7 = outing ts Talper = 2 Mounting Bots Rear Talper WT z = rake Hose Bono Bot Tater a a = Brake Hose Beno Bot ear Wheel Gyinder 7 7 = Mounting Bots Weel Gyinder 6 7% = Broke Line Paring Sake 7 7 = Parking Bake 7 7 = Lover Sack Bote Parking rake 1 = 7 cable Reiner Hut5-8 BRAKES - BASE BRAKES - BASE (Continued) SPECIAL TOOLS BASE BRAKES. Installer Caper Dust Boot C-4842 Adaptor Cap Pressure Bleeder 6921 1 BRAKE LINES DESCRIPTION Flexible rubber hose Is used at both front brakes and at the Year aale junction block. Double Walled Ste! tubing fe used to connect the master elindr 2 {the major hydraule broking components and then to ISO sige fares sre weed on the bake lines OPERATION ‘The hoses. and tines tranomit the brake fd inders DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES Fletble rubber hase Is used at both front brakes ‘and tthe rear ade jetion black. Tnspeet the hoses ‘whenever the brake system is servied, at every engine all change. or whenever the vehicle 1 in fr rape the ses for surface cracking, suffi, o sworn spots, Replace any brake hose ininediatly if the Iabrc casing of the hose ts exposed de teak ‘Aso check brake base itllation, Faulty ins ‘with the wheels ond tires or ether chesis compo racking and eventual fate ‘The steel brake lines should be inspected. period cally for evidence of corrosion, tists Kinks, leaks. or fther damage, Heavily corroded ines will eventually fn thou caning lake. In any cae, coreded oF ‘emage! brake lines should be replaced. Fectory replacement brake ines ad hoses are roe ‘xnmended 1 eosure quality correct length ad supe that brake line and hose mating surfaces are clean land free from nicks and burrs. Also remeber tha ‘ai and let brake aes are rat interchangeable, (Use new copper sel weshers at ll ealiper canner tions, Be sure brake line conection are properly nade (no cross threaded) and hghened 10 recom ered oraw BRAKE LINES (Continued) STANDARD PROCEDURE ‘STANDARD PROCEDURE - BRAKE TUBE FLARING etered forall repairs, However, double wall st tube can be used for emergency repalh when TaEory ‘Speco bending cols are needed to avoid kinking ‘or ninting of metal brake tubes, Special arg tals lire needed to. make a double inverted Mare or ISO Hare ie 2h Fig. 2 Inverted Flare And 180 Flare STANDARD PROCEDURE - DOUBLE INVERTED FLARING ‘A preformed metal brake tbe is commended and prefered forall repairs, However, double-wall tel {abe eon be used fr emergency repair when factory 1H) Cut ff damaged tube with Tubing Cutter. (2) Ream cut edges of tubing «0 ensure proper M3) Install replacement tube nut on Ue eae (a) ert tae in flaring tol, (5) Place gauge form aver the end of the tube (6) Push tubing through flaring too jows un tube diameter. BRAKES - BASE 5-9 (7) Tighten the too bar an the cube (8) Insert plug on gauge In the tube, Then swing ing srrew in recess of compression dine (Fy 3) io) Tighten tcol handle unl plag gauges squarely sated on ans of faring tok This wl start (U0) Remove the plug gauge and complete the snverced fare Fig. 3 Inverted Flare Tools ‘STANDARD PROCEDURE - ISO FLARING prefered forall repair. However, dousle-wall tel {ie be er emer ea whe ary "fo make a 80 fare une » Flan Tol it (0) Cut of damaged tube with Tang Cater {2} Remove any burrs from the inside of the tube te top of the tol bar (Fig. 4. Then tighten the ta thar othe tbe, (9) stall the corect size adaptor on the flaring i Lubrieste the adap5-10 BRAKES - BASE BRAKE LINES (Continued) (7) Align the adaptor and yoke serew over the tube ig. 4) 1) Turn the yoke serew in until the ecdeptor 1s scqarely seated om the tol bar @ ‘® Fig, 6150 Faring DISC BRAKE CALIPERS DESCRIPTION “The calipers are a single piston type. The calipers ‘re fre to ade lterally th alls camino come pensaton for lining wear OPERATION When the brakes are applied Mud prssure 1s ‘exerted agains the caliper piston. The utd pressure iR'nerted equally and inal directions. This mess Pressure exerted against the caliper piston ond Wit the caliper Dae willbe equal (ig 5) hit pressure applied tothe piston fx transmitted ‘ircty to the Ininard brake shoe. This forees the Take rotor. At the same time, uid pressure within the pistn bore forces the caliper to Side inward on 1 ng ta get ae the dss brake utr In summary, fad pressure acting simultaneously ‘on both pst and caliper prosuces'a sing camp 1 ® © © ve Fig. 5 Brako Caliper Operation ing action, When sulficent force 4 applied, ition Wil attempt to stap the roturs fom turing and bring the vehicle to stop Piston. Upon release af che pedal. che caliper and ps ton recur toa rest position The Brake shows donot sons for ths are to keep rood debris from geting, Teween the rotor and ining ai in wiphng he rotor “The caliper piston seal crtrls the smut of ps: ton extension perded to compensate for normal Titi, During brake apliatan. the sea fs defied at ward y Tat presnare snd pston moversent Fp. 6) ‘When the Brakes (and fd pressure) ore released the ‘al relaxes and retracts the plson the ainoune of seal deflects. Genecally the amaust te ust enwugh to maintain contact between the ple3) races = case 5 DISC BRAKE CALIPERS (Continued) (6) Remove brake hose mounting bolt and discard washers lg 8) REMOVAL, wowe REMOVAL - FRONT Fig. 6 Brake Hose And Bolt (8) Drain small amount of (a) Bolton caliper piston i bore with Clamp Position clamp sew an eutbegrd brake shoe and lamp trane on ear of ealiper (Fig. 7) Do not allow Fig. 9 Caliper Mounting Bots ‘ig. 7 Bottoming Caliper Piston With C-Ctamp5-12 BRAKES - BASE DISC BRAKE CALIPERS (Continued) (1) Tie op of caliper outward with pry toa ne: essary (Fig 10) and remove caliper Fig. 10 Caliper Removal (8) Remove caliper fom voice. REMOVAL - REAR (0) asta prop tad om the brake pedal wo keep presure on the brake syste. (2) Raise and support vec (3) Rereve the wal and tre assembly (a) Rerove the brake hose banjo bolt replacing caliper (G) Remove the callper mounting se pn bok (ig. 10, (6) Remove the caliper from vehicle Fig. 11 CALIPER MOUNTING 1 DISASSEMBLY (0) Remove brake shoes trom caliper: (2 Drain brake uid out of caliper (3) Take a plece of wor! and pad It with oneanch thickness of sap tanels: Place this piece tn the ut oor! shee ide of the caliper infant of dhe piston ‘Ths will cushion and protec caliper piston uring, removal (Fig. 12) Fig, 12 Padding Caliper Interior (0) Remove caliper plston with shore bursts of lo pressure compressed air Direct alr trough Maid Ine por aa ease pista at of bere (Fig. 13) CAUTION: Do not blow the piston out of the bore ‘with sustained air pressure, This cou resut in ‘racked piston. Use only encugh air pressure to ‘esse the platon out. WARNING: NEVER ATTEMPT TO CATCH THE PIS- IN PERSONAL INJURY.BRAKES - BASE 5-13 w DISC BRAKE CALIPERS (Continued) Fl. 15 Piston Seal Removal zi es) ue en é Fig 16 Mounting Bort Bushing And Boot CLEANING thinner, oF These products may Inave residas that could damage the piston and INSPECTION CAUTION: if the caliper piston is replaced, install " p2 of piston In the caller. Never Inter- change. phenolic resin. and stel caliper pistons The als, seal grooves, caliper bore and5-4 BRAKES © BASE it DISC BRAKE CALIPERS (Continued) ‘The bare can be Lightly polished with a brske _(f} Install new piston seal into seal groove with hone to remove very: minor surface Imperfections niger (Fig, 19) “severely corre, rusted. scored. or if palishing rease bore dimnter move thant 0125 re Fi. 19 Piston Seal instalation Fig. 17 Polishing Piston Bore eee ________ pen Howe (6) Install new das bot on clipe piston and seat paren aut in piston grove (ig, 20) [ASSEMBLY ‘CAUTION: Dir, ol, and solvents can damage call er seals. Insure assembly area Is clean and dry. (1) Labricate caliper piston hore, new piston sal sid piston with slam brake Ma (2) Lubricate caliper bushings and Interior of wos Fl. 20 Dust Boot On Pistonw DISC BRAKE CALIPERS (Continued) (©) Press piston Inta caliper bore by hend, use 8 INSTALLATION tur and push motion to work plston into seal (Fg 2 BRAKES - BASE 5-15 INSTALLATION - FRONT a Fig. 28 Caliper Lubrication Points Fig, 2 Piston Dust Boot instalation dss bow recesses Eee Fig, 24 Caliper instalation "9°05 (0) Replace caliper bleed serew if removed a euueeinc as il iciac vane cies5-16 BRAKES - BASE DISC BRAKE CALIPERS (Continued) ) Coat caliper mounting. os swith scone grease, Then Install and tighten bole 15 Now (1 Nts) ‘CAUTION: Ht new caliper bolts are being Installed, ‘oF Ifthe orginal reason for repair was & drogipull onal, check caliper bolt length before proceed: ing. Bots must not have a. shank Tengtn greater than 67.6 mm (266 In} (Fg. 26). ; ® Eo) o—}+—+ Fig, 25 Mounting Bolt Dimensions (4) Kosta brake hose caliper with mew. seal washers and tighten ing batt SE Naw (23 0 Ts. CAUTION: Verity brake hose is not twisted or inked before tightening fiting bot (9) Bleed bose brake system. (Refer 5 BRAKES, STANDARD PROCEDURE (t) Intl whee and ten assembles (Rler to 22 ‘TIRESWHEELSWHEELS STANDARD PROCE DURE, (7) Remove supports and ower vee, (8) Verify Fer pedal belore moving vehicle INSTALLATION - REAR (A) Install the brake pads i renuved (2) Lobricate antatte ips lor the aise brake pds (Fig. 25) (3) Install caliper ta the caliper adapter (4) Cont the caliper mounting slide pin bole with salle grease. Then Install and tighten the oles 12 15. (11 ts) (@) Install the brake hose banjo bot removed ie 27) (6) tata the brake hose seal washers and tighten Ft Tbs), ipbolt to 31 New (23 1 Fig, 26 ANT-RATTLE CLIPS ‘CAUTION: Verity brake hose ie not twisted or kinked before tightening fiting bolt. Fig. 27 CALIPER INSTALLED (7) Remove the prop ra rom he vee (B) Bleed the dase broke system Refer to 5 BRAKES - STANDARD PROCEDURE) OR (Refer to 5 BRAKES - STANDARD PROCEDURE) (0) esta We whet and tire assemblies (eter to 22 TIRESWHEELSWHEELS - STANDARD PRO. ‘CEDURR) [U0) Remove she supports and lower the vehicle (U1) Very fem pedal before ening the veilw BRAKE PADS/SHOES REMOVAL REMOVAL - FRONT PADS (0) Raise and supe vehicle (2) Remove wheel an ire essombly (3) Remove caller (Refer co.» BRAKESIY: DRAULICMECHANICALIDISC BRAKE CALIPERS, REMOVAL, (H) Pressing one end of qutboard shoe inward ta crepes son The ate stow up shoe tnwat ta disengage shoe ug and Taiate shoe up fad out af alpen Pi 2 Fig, 28 Outboard Brake Soe Removal (9) Grasp ends of iniaard she apa dt shaw out ward io release springs from caliper pistan (Fig. 29) land remoxe shoe fram caliper brake shoes will be used, he ‘pd right. They are not in NOTE: orig them in sets le changeable (©) Secure caliper 10 nearby suspension pare with ‘wire Do not allow rake hese to support caliper ‘weight (Gh Wie caliper of with shop rags a towels [GAUTION: Do not use compressed alr, this can Uinseat dust Boot and force dit Into piston bore REMOVAL - DRUM BRAKE SHOES. (0) Raise vehile and remove rear wheels Fig. 29 noord Brake (2) Remove and dscord. spring ues securing, (3) Remove brake drums. NOTE: I drums are dif cult to remove, back off ‘adjuster though support plate access hole with brake tool and soreweriver. (4) Remove Usp and washer securing adjuster cable to parking bake lever TF 3) 15) Remove primary ond secondary cotarn springs from anchor pin with brake spring pliers 1) Rome Pn song rare a pe {7 Install spring camps oa wheel cylinders 1 hol pistons i place (@) Remove adjuster lever, adjuster screw and (0) Remove adjuster cable and cable ute U0) Remove brake shues and parking brake strut (U1) Disconnect eat rom parking Brake lever REMOVAL - REAR DISC BRAKE PADS (4) Raise and supprt vehicle (2) Remove the wheel an ire aserbes {3} Compress the caliper [a] Remave the caliper Refer w 5 - BRAKESIHY. REMOVAL). (6) Remove the caliper by cui the op up and oft the caper adapter NOTE: Do not allow brake hose to support caliper sembly.5-18 BRAKES - BASE BRAKE PADS/SHOES (Continued) ‘SRREE RSRENDLY 1 19905.12 Fig, 30 Drum Brake Components—Typleal (©) Support and hang the elie (7) Remove the Inboard brake pad fom the ealiper (@) Remove the outhoard brake pad from the cl ver adapter INSTALLATION INSTALLATION - FRONT PADS (1) Install inboard she in caliper and verify shoe retaining fly seated in the pista (2) Searing one end ef cutboard shoe caliper ‘and rotating shoe downward Inta place, Verify shoe (3) stall cali’ [eer to 5. BRAKESIHY. DRAULICMECHANICALDISC BRAKE CALIPERS. INSTALLATION). (a) Entall whee! and ‘TIRESWHEELSWHEELS DURE) (5) Remove support ant lower vehicle (©) Pump brake peal unt caliper plstons and S'STANDARD PROCE (0) Top off brake Mad level If necessary. INSTALLATION - DRUM BRAKE SHOES (1) Clean suppart plate with brake elesner (2) tne drums are being installed. remove po tether ane ke (3) Apply mule-purpose grease to brake she con tac wofnees of support pate (Fig) (a) Labrieate adjuster serew threads and_pivet 13) Attach parking brake lover to secondary broke she. Use ew washer and Ucip to secure lever 10) Remove whee! cyte clans (7) Attach parking Brake eable to lever (8) Insta Brake shoes om suppor plate. Secure shoes with new holden springs, pins ane Fae {o) install parking broke strut and spring. (UO) Install -guide plate and adjuster cable on anchor pin {11 rst primary and secondary return springs (02) Install "adjuster "cable ue on seomdary shoew BRAKE PADS/SHOES (Continued) 9005-14 Fig 1 Shoe Contact Sutaces (U3) Lubricate and assemble adjuster screw (04) Install adjuster screw. spring and lever ond (U5) Adjust shoes to drum. Refer @ 5 - BRAKES HYDRAULICMECHANICALDRUM. = ADJUST. MENTS) (U0) Install weheettire asemblos ae lower veh de. (Refer tg. 22 ~ TIRESMWHEELSWHEELS STANDARD PROCEDURF) (17) Verfy Rim brake pedal before moving vehicle INSTALLATION - REAR DISC BRAKE PADS (0) Botom pistons in caliper bore with Camp. Place an oll brake shar between 2 ©-lamp snd ea (2) Clean caliper mounting adapter and enc-rate springs. {@) Lubricate antratte springs with Mopar broke (A) Install anté-atle springs NOTE: Antiatie springs are not interchangeable, (6) nse intoard brake pad in adapter (6) natal eutboard brake pad in adaprer. (0) Tie he tp af the caliper oer rotor and under adapter. ‘Then push the bottom of the caliper down (nto the adapter (8) Install caliper, [Refer to 5 - BRAKESIHY. DRAULICMECHANICAL/DISC BRAKE CALIPERS, INSTALLATION). (9) Inia wher and tice ansebles ar! tower Yehise. (Refer tp 22.” TIRESNHEELS WHEELS STANDARD PROCEDURE) (U0) Apply brakes several tines to sea caller pl tons und brake shoes are tain fie pedal (U1) Tap olf master cylinder Mud level BRAKES - BASE 5-19 DRUM DESCRIPTION The brake systems use a leading shoe (primary ‘and wai, stae (secondary) The muni, har ‘ware fs sian but not interchangeable Fig. 30, OPERATION ‘When the brake pada is depressed hydraulic res sure pushes the rear brake wheel einer pistons futward. The whee eyinder push ros then push the brake shucs outward against the brake drum. When {o the brake shoes pull the shee bock to there oi Ina positon. (Fi, 30) DIAGNOSIS AND TESTING - BRAKE DRUM RUNOUT ‘The minum allowable diameter of the drum taking surface i indicated onthe drum auter edge GGenevaly.a drum can be machined toa maximum of 152 mn (0060 in) oversize. Always replace the rum if machining would ese drum diameer to ‘vce the size lt tiated nthe dem, [BRAKE DRUM RUNOUT Measure drum dinmeter and runaut with an ac rate gauge. The mst accurate method of measure rent involves mounting the drum ina brake lathe ‘Variations in drum diameter should not exceed (0069 nim (00028 In). Drum nat shuld no exceed 018 tm (0.007 tn) cut of round. Mache the hn if ruwut or verlation exceed ese, vs Replace the drum if mactning causes the drum 1 ‘exceed the marina allowable dameer ‘STANDARD PROCEDURE - BRAKE DRUM (MACHINING “The brake drums can be machined am drum lhe ‘when necessary. nal tnachining euts shuld be tin Teed to 120.20 mm (2005 "0.008 in) ata time as Ineaver feed rates” can produce taper and. surface arian Final finds of O85 10 O38 mm {O00r to 0.0015 in) are reeammended and wil gen erally provide che best surface Tish flvays be used around the dram to reduce vrata Sand avoid chatter marks. The maxinm allowable dlamcter of the dram cuter edge.5-20 BRAKES - BASE DRUM (Continued) ‘CAUTION: Replace the drum if machining wil cause the drum to exceed the maximum allowable dime: CLEANING the suppart plate and wheel eslinder exterir. with water dampened cla or with brake clesner. Do noc tse any ote clearing agents: Renae ight rust sid ‘cole from the brake shee contact pads on the sup INSPECTION replace hen wr to within O78 sm (062 a) of the rivet heeds Bonded ning shouldbe replaced ‘when wor toa thickness of 1 xm (U/16 Jn) Examine the Hyg contact pattern to determine i te shoes are bent the dr fs tapered The ning, ‘should exhibit contact across its entire width, Shoes fexhibidng contact only “on ave sie shouldbe inpect the adjuster screw assembly, Replace the assembly ithe star wheel or threads are daa (Gr the companents are severly rusted or carried Discard the brake springs and retainer components st worn, distorted or callaped. Also replace the ‘springs Ifa brake drag candtion hod occurred. Over Heating wil stort and weaken the spring, plete replace the support pate itany af the pads are ‘worn or rusted threugh, Aso replace Ue pate Its ig. 32 Shoe Contact Suraces 1 ADJUSTMENTS - REAR DRUM BRAKE Justin mechani Ur natal cestance, he Sly tine adustnent ts required bs when the shoes ep em oy ep ‘duistment canbe made with standard she gauge or with adjusting too Adjstinent pr. formed wih the compete bake assem stale ADJUSTMENT WITH BRAKE GAUGE (1) Be sare parking brakes are ally essed (2) Raise rear of wehie and remove wheels and ‘rake drums (3) Verify thet foe and right automate adjuster levers and cables are property connected (a) inert brake gauge im drum. Eqs age lun gouge inner Tegscantet drum braking surface “Then face gauge In poston (Fig. 38 ig, 33 Aajsting Gauge On Drum (6) Reverse gauge and install (ton brake shoes Peston gauge loge at shee teers ss shown (Fig 23) It gage doesnot ft (oo Toston gh, ads Shoes 16) Pall shoe sajuser lever away’ from adjuster (7) Turn adjuster srew star wheel (by hand) 10 ‘expand or retract brake shoes, Continue adjustment ‘unl gauge outside legs ae ight dragon shoes. Us) insta ake drums aad heels an ower chide, (8) Drive veicle ard make one forward stop fl lone ean sop Rot re 810 ‘acjasumentFig. 24 Acjusting Gauge On Brake Shoes NOTE: Bring vehicle to complete standstit ‘stop. Incomplete, Sulomatie adjusters [ADJUSTMENT WITH ADJUSTING TOOL (0) Be sure parking brake lever fully released (2) Raise vehlle so rear wheels con’ be rotated (3) Remove plug from each access hole in brake support places. (i) Lanse parking brake cable adjustment nut 1G) Insert adjusting tool through support plate ‘access hele and engoge tool i teth of sting Screw star wheel (Fig 33) (G) Rotate mijuster screw star wheel (nune tol handle upward) unt Sight drag can be ft when ‘wheel is rotated (7) Push aid bold adjuster lever away Fem star (8) Bock of eduster sew stae wheel until broke rag ts linn. [eget ayers aap whee De sre (U0) Tastal support plate access hole pugs U1) Adee parking brake cable and tower vehicle 12) Drive vehicle ad make one forward! stop fl lowed by ene reverse stop. Repeat procedure 10 times co operate automate adjusters and equalize ‘adusenent BRAKES - BASE 5-21 Fig. 38 Brake Adjustment NOTE: Bring vehicle to complete standstil at each ‘top. Incomplate, roling stops wil-not activate ‘automatic sejustors. FLUID DIAGNOSIS AND TESTING - BRAKE FLUID ‘CONTAMINATION Swollen rubber parts indicate the presence of peruteum in the brake Md. "Totes fr conarinatin, pt sna deained brake fluid in lear glass ar I tates inte layers there is mineral cl or ether fad ‘cotamination of the brake fl TT brake Maid Ie contaminated, drain snd thor: cughiy Mest sytem. Replace master tine propor tioning. valve caliper seals, wheel ytinder” sal, Antilock Brakes, hydravli unit snd all hydraule5-22 BRAKES - BASE FLUID (Continued) STANDARD PROCEDURE - BRAKE FLUID LEVEL. ‘Always clean the master cylinder reservoir ond cet ei cen Hl eve Ira dead, de "The fad il level is tiated on the side of the master einer reserva Fig 36) cet ha 5 he FUL tr on proper level Fig. 36 Master Gylinder Fluid SPECIFICATIONS BRAKE FLUID “The brake fluid uaed in this vehile sms conform to DOT 3 specifications and SAE. 11708 standards Np other ype of brace fluid is recammended or ‘epproved fr touge in the vehicle brake ayo Use Mopar beake uid or en equivalent fm @ Uighly stated container ‘CAUTION: Never use reclaimed brake fluid fad ‘Wom an container which has bean let open. An ‘open container of brake fui will absorb moisture ‘rom the ir and contaminate te fd CAUTION: Never use any type ofa petroleum-based {ui In the brake hydraulle system. Use of such ‘ype fulds wl result In seal damage of the vehicle brake hyeraulic rystom causing a fare of the ‘Vehicle brake system. Petroleum base Muice wo be items such as. engine oll, ansmission Ml power stesrng fu, ste 1 FLUID RESERVOIR REMOVAL (0) Remove reservoir cap and empty uid into {2} Remove pins chat retain reservole to master cinder Use barnmer and pin punch te remove pins tig 3m, Fig 37 Reservoir Retaining Pins (9) Clamp cylinder body in vise with base protec uve jas. Ua) Laem reserva fom grommets with py tl ) ‘ig, 38 Loosening Reservoirw FLUID RESERVOIR (Continued) (©) Remove reservoir by rocking Itt one side nd paling fee of grommets (Fg 39) Fig, 39 Reservoir Removat (@) Remove old grommets from cylinder body ig 0) INSTALLATION CAUTION: Do not use any type of too o instal ‘rommets. Teals may cut, of tear the grommets cree ‘ting 2 leak problem afior installation, Install the ‘rommets using finger pressure only. (1) Lubricate new grommets with clean brake Had ‘and Install ew gromneta im einer body (ig. 4, Use tiger pressure to instal and seat grommets (2) Sear reservoir n grommets. Then rock reser (Install pins that retain reservoir to oyinder vac (4) Flan bleed master eter on bench before Fig. 41 Grommet instanton MASTER CYLINDER DESCRIPTION ‘The master eylinder as a removable nylon reser voir The cylinder body made of alusinunt and tans a primary and secondary piston assembly sre mt sersienble. I diagris fdas a internal problem withthe elinder body. must be replced [san assembly Toe reerear and grommets are he ‘OPERATION The master cylinder bare contains primary ae Tyaeoule pressure othe front brakes. The sccanary ‘ston supplies hydraulic pressure tothe rear brakes {hai for the Rydal brake ret DIAGNOSIS AND TESTING - MASTER CYLINDERIPOWER BOOSTER (1) Start engine and check booster vecwu Correct any vacuum les belore paced (2) Sip engine aad shift wanssion ny New wal, (3) Pump brake pel ni ll wecuui reserve In {a} Press and hold brake pedal under tight foot pressure The pedel should old frm, if the pedal Eee 7 i 1S) Start engine and note pedal action. It should Fall away slightly under tt fot pressure then hold fim: If na pedal action i dscerible, power basse, hose5-24 BRAKES - BASE [MASTER CYLINDER (Continued) ‘vacuum supply, or vacuum check valve ts fulky: Pro ‘ceed tp the POWER BOOSTER VACUUM TEST, (@) Ir the POWER BOOSTER VACUUM TEST posses, rebuild bouster vacuum reserve as fll Release brake pedal. Increase engine speed to 1500 2) Waite inary of 90 seconds and try brake action agin. Baoster shuld provide two or more vac sae ped pica fc ss POWER BOOSTER VACUUM TEST (Q) Connect vacuvin gauge to Boston check valve with short lengh of ose and Titi (Fg. 2). (2) Start and run engine a cub ile speed for one 1) Observe the vac sap Hvac apy Clamp hose shat been vacuum source and eck valve 1G) Stop engine and observe vacuum gouge (6) Ir eacuum rope mere than ane ened HG (33 riers) within 15 seconds, boster dapheagen or ‘eck vale Is Tally, Fig. 42 Typical Booster Vacuum Test Connections 1 POWER BOOSTER CHECK VALVE TEST (1) Discont vac hese fram check valve (2) Remove check valve and valve Seal (rom booster 13) Use a hand operated vaci pap fr test, (8) Apply 15.20 inches vacuum ft large nad. of cick valve ig. 4, (2) Vacuum should hold stead I gauge on pump Ng? < Fig, 43 Vacuum Check Valve And Seal ‘STANDARD PROCEDURE - MASTER CYLINDER BLEEDING ‘Anew master linder should be bed elore instal Jaton onthe veel. Required bleeding teas che Bet tubes cam be fabricated fron brake Tie {0} Mount master einer vse (2) Attach ‘bleed tubes to cinder outlet ports Then posi each cue ei no the reservoir (Fi an) (3) Fill eservoie with fresh brake Mad {a} Press evlinder pistons rar th wood dowel “Then release pst ad al then retard pring presure: Cantinee Bleeding operatians ntl ir bubbles are no longer visible tn Nd REMOVAL {U) Remove evaporative canister (2) Disconnect brake lines to master cylinder and combination valve Fi 45) 13) Remave corabinstion vale backet maunting ula ed ronere vale 1s) Remove master ylinder mounting. mits and remove master evlinder (3) Remove eyder cover andw [MASTER CYLINDER (Continued) Fig, 44 Master Cylinder Bleeding Fig. 45 mast INSTALLATION NOTE: I master cylinder is replaced, bleed cylinder before Intalition (1) Remove protective sleeve from primary piston sha on new master ender (2) Check cancion of seal a rar of eyinder bay Reposition sal i dsldged. Replace seal if xt, (3) Install master ytinder ona brake taster studs nd tighten mounting puts to 17 Naw (13 Ts NOTE: Use only exiginal or factory replacement RAKES ~ BASE 5-25 (4) Install combination valve onto brake booster stds and ghten mounting mats 20° N18 Te Ths) 13) Install brake lines to master eyinder are om ination valve by bend wo avai ess threading {G) Tighten master eyinder ake lines to 19) Nm (tht (7) Tighien combination valve broke lines 19 19 Nan (14 Ibs) (6) install evaporative canister (0, Bice base vale system Ref STANDARD PROCEDURE) PEDAL DESCRIPTION ‘A suspended-sype brake pedals used, the pedal racket The bracket te attached tothe dash pal “The brake pedal assembly and pedal ped are the only serviceable companent, ‘OPERATION ‘The brake poval is attached to the booster push ral"When the pedal i. depresed, the primary cater secondary red. The buster secondary fod Sepresses the master eylinder piston REMOVAL (1) Remove negate battery cable (2) Remove brake lap switch (3) Remove ABS cantrler i equiped (a) Remove retainer clip securing, booster push red to pedal tFlg. 46) and clutch rod retainer clip If cloned (3! Remove bols from brake pedal support and toceter mounting nuts, Remove mounting tod plate nuts or clutch ejinder mounting nate i equipped, FG) Sit ear mtrmater nde herby (7 Remove mexsting stad plate or sid chute inden forward i equipped 18) Tit the pedal support down to gin sf clear (0) Remave pedal shaft Clip trom passenger side ofthe shat. 10) Side the peal sha toward the drivers side and remove the remaining Clip, Ui) Sid the shaft cul uf the pedal racket ane remnave the peda 12} Remave pedal bushings Mf they are &0 be5-25 BRAKES - BASE PEDAL (Continued) ® Fig 46 Push Rod Attachment INSTALLATION (1) stall ew bushings in pedal Lubricate bush ings and shaft wth ultypurpise grease 12) Poston pedal in bracket and Install haf (3) Install new pot pin Clip. (a) Poston peda suppor aa sal supp ols ‘and eighten to 28 Nem (2 Ths (@) Sh the boostermaster «ylnder assembly into ples, install mounting nuts nd tighten 38 Nm (208 the (G) Tntail stud plate or uch eglinder equipped and igen mounting mt 028 Nam (21 Tbe} Install retainer clip soiring footer push rod to pedal (Figs 40) and. etch od retainer hp it ‘quipped (7h install ABS controler i equlpped (8) tnstall and connect brake lamp switch (0) stall negative battery cable 1 POWER BRAKE BOOSTER DESCRIPTION The booster assembly consists of hausing vk ‘The outer edge of each diaphragm setae (othe booster housing "Tw ph res are use i the booster The pt mary’ push cod canects Use buster tothe beske pedal. The secondary push ed carnects Use bonser {o the maser cylinder ta stroke the ender pItons OPERATION ‘The stioepherte inlet valve is opened and closed by the primary push rod. Basser vacuum supply is age ata to a ake marl ig ft one edad to the booster check valve at the “ther The voc chec valve in the buster housing {Sinene-way device that prevents vara leak back Power ssist fs generated by utilizing the pressure ‘erential between normal” stnwspieri.presoure land vacuum. The vaca needed for booster sper: ‘ation i taken diretly rom the engine intake mank through iter and inlet valve ac the Fear of the using (Fig. 7) “The chamber areas forward of the bopster da {aalld. The chamber areas tothe rear of te da rags. are exposed to normal atnonpheri pres ‘Sire of 101.3 ilopscals (17 poundssquare In). ‘lo open the atmospheric inter valve This exposes the area behind the dlaphragins to atasphere ees “The tester check valve, check valve grommet ann cater seals are serviceable,w BRAKES - BASE 5-27 POWER BRAKE BOOSTER (Continued)5-78 BRAKES - BASE POWER BRAKE BOOSTER (Continued) REMOVAL (u) Remove combination vahe and master cinder (2) Discomect vaciuen hese front booster chee, valve. (3) Remus retaining clip thst secures. booster push ro to Brake pedal (Fg. 48) andi the rod Tal Remove four nuts attaching baoser 10 front ‘awl panel (Fig. 48) (5) im engine campartoent, se booster Sts out ot cow! panel and remove the booster fra engine eomporaient (e) Rem Q M - Fig, 48 Push Rod & Clip Fig, 49 Booster Mounting Nuts 1 INSTALLATION 0) Clean he taoster menting surface (2 Install dash seal om booster. (8) Align and postion booster on the font cowl panel TH) In passenger compartment, otal ts th attach booster te dash pane! Tighten ts nought had booster In place {Gi Lubricate the pedal pin and bushing. with push rod nto brake pedal pin ond. secure with Fecaning lp. (6) Tie booster mounting mits to 59 Nim (29 tbe (7) Comet vacuum hose te taster beck vale (8) Install master eyinder and combination valve. (0) Top off master eylloder Mud evel and bleed COMBINATION VALVE DESCRIPTION ‘The combination valve contlns a pressure difer: cna valve and snitch anda rear brake proportion replaced a8 an assembly if diagnosis indicates this is OPERATION PRESSURE DIFFERENTIAL VALVE “The presure diferent! switch is connected to the brake Waring ight. Te sulted actuated by move ment of the itch valve. The switch monitors fuid pressure in the separate froneat brake hydraulic Iydeaule reat will cause the sich valve to shat tte to the low pressure side, Movement ofthe valve Irushes the switch phages upward This ation loses ‘arert tothe red warning igh The seh vave wl Fetal ian actuated poston una repalrs to the PROPORTIONING VALVE “The proportioning valve used tbalanee font sear bre etiam at high deceleration. The valve lows nora fad Tow daring waoderate braking, “The valve ony controls fd ow during high dec rations brake stopsw COMBINATION VALVE (Continued) DIAGNOSIS AND TESTING - COMBINATION VALVE Pressure Differential Switch (0) Have helper sit in divers seat to apoly broke pedal ed observe re brake warning ight. (2) Raise vehicle on hus. (3) Connert eed how toa rear whee cylinder with brake Ma (a) Have helper press and bol brake pedal ta oor and observe warning igh. (a) Tarn Hh anates, swith is opera ing corey Io) Tr ight asc turinae, coe eeu fas, Tight bulb and fuse i funcional, Repairer seplace parts as necesary and tes diferental presse Eich operation again (G1 1 warning ight til dees oot swith s Tat. Replace cambinaton valve assembly bleed brake system and verify proper site ond REMOVAL 0) Reriee brake tines that connect master ein der tovcambination valve Fig 90) (2) Disconnect rake line thet connect combine tion valve to front and rear brakes 1G) Disconnect wire fram combination vake switch aged 1G) Remove rats attaching combination valve Toten studs ig Si) INSTALLATION (1) Pesan valve bracket on bouster studs a lighten bracket attaching nuts to 20 Nin (15 TBs) 12) Align and start brake Tine Rings tn cambina tion valve and master elinger by hand took! eres (3) Tighten broke line fitings at combination valve 119 Nem ttf Ibs) Fig, 50 Combination Valve/Master Cynder Fig. 51 Combination Valve Brackot (3) Tighe brake line tings at master eytinder tol19 New (Ld fib (6! Conett ice to dilferertial pressure sth i (6) Bled hese brake system. (Refer w 5 - BRAKES. STANDARD PROCEDURE5-30 BRAKES - BASE ROTORS DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - DISC BRAKE ROTOR Tight surface rust and scale can be renee with lathe equipped with ial sanding discs The rotor Replace the rotor under the Tollwing conditions = Sownrely Seared 2 Cracked 1 Below Minimum Thickness ROTOR MINIMUM THICKNESS Measure ror thickness a te center of the brake sie tn ra Race he rn Bele Rotor minimum thickness ts usually spectiod on the rotor hub. The specication Is ether stamped or ROTOR RUNOUT ‘Check rotor lateral runout with dial in (€.359 (Fig. 52. Excessive Intra runout wil case lake peda pulsation and vapid, uneven Wear ofthe brake ‘shoes Pesition the dal inlestr. plunger ‘approximately 264mm (Lin) snward frm the ator NOTE: Be sure whee! beating hi before checking rotor runout. 2010 end play (0.008 int ROTOR THICKNESS VARIATION Meesure rotor thikiess at 6012 points around the rotor face (Fig. 33 Psitan the micrometer approximately 25.4 mm (1 “Thickness should mak vary by mare than 8.012 am (0.0005 In) from pol pent onthe rotor. Machine 1 oO Fig. 52 Checking Rotor Runout And Thicke Varstion Pm ao Fa, 89 Measuring Rotor Thickness DIAGNOSIS AND TESTING - BRAKE DRUM IN HAT ROTOR: ‘Anny replace the dunn macuning would case drum diameter to exceed the sie init indeated ot ‘BRAKE DRUM RUNOUT Measure drum diameter and rant wth a acu raters The mnt arate met farew ROTORS (Continued) Machine the drum if ranout or varlation exceed values. Replace the dram in hat rato if machin STANDARD PROCEDURE ‘STANDARD PROCEDURE - DISC ROTOR MACHINING The de brake rotor can he machina Hf scared o worn, The lathe must machine bath sides ofthe rear Simuleaneausly with dual cutter beads, The tor routing surface must He clean before plang othe Inthe. Equipment capable of machining only are ide a a ine may produce a tapered rotor mended, This type of lathe tues the rotor to the ‘etieles hubs ‘CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machi tmust be replaced STANDARD PROCEDURE - BRAKE DRUM IN HAT ROTOR MACHINING “The brake drum tn at rca can be machined na shh be Hite! 0 0-12 0.20 mn (0.005 ~ 0.008 in) fa tine es heavier fed rates can produce toper and Surface variation, Fial finish cuts of 01025 to 0038 tw (0001 t0 0.0015 in) are recedes are wi Ieneraly provide the bet surlace iss Be sure te deur shat ror is securely mounted tn the lathe before machining operations. damper sop shoul abayr fe hed re he eo “The wianumallawable diameter ofthe dram braking surface is stamped or cst into the dru in hat rar ‘CAUTION: Replace the drum In hat rotor Hf machin- ing wil cause the drum to exceed the maximum ‘towable diameter. REMOVAL REMOVAL - FRONT (0) Remove wheel and tire assemble (2) Remve caliper (Refer to 5 - BRAKESHHY. DRAULICMECHANICALIDISC BRAKE CALIPERS. REMOVAL RAKES - BASE 5-31 (3) Remove retainers securing rotor to hu studs ig. 58) (3) It roar shield requires sevice, remove front Ihab and bearing assert REMOVAL - REAR (4) Raise and support he vehicle (2) Remove the tie and wheel assembly (Fig, 55) Fig, 55 ROTORIGALIPER5-32 BRAKES - BASE ROTORS (Continued) () Remove the disc broke caliper and pads (Reer to\§.» BRAKESIYDRAULICMECHANICALDISC BRAKE CALIPERS REMOVAL} (a 3), Fig, 86 ROTOR (4) Remove the retaning clips and rotor assembly INSTALLATION INSTALLATION - FRONT (0) I nee rotor fs bong installed, remove pote ‘deaver {21 stall rotr on hub. (3) inal ‘aliper Reier to 5. BRAKESIHY. DRAULICMECHANICALIDISC BRAKE CALIPERS, INSTALLATION. (4) Install wheel and ire essombly. Refer to 22 LSWHEELS STANDARD PROCE INSTALLATION - REAR (0) nstall the sot a te axteshat. (2) install the dive brake caliper nd pads (ig 54), (Refer w 5 BRAKESIHYDRAULICMECHANI (2) tll the tire aed wheel assembly Refer to 22 TIRESWHEELSWHEELS - STANDARD PROC DURE, (4) Lower the vehicle 1 WHEEL CYLINDERS REMOVAL (1) Remove wheel and ire assembly (2) Remave brake drum. (3) Remove wheel eyinder brake ne (a) Remove brake shoe return springs ond wave IG) Remave cylinder attaching bolts and remove cinder from support plate DISASSEMBLY (0) Remave push rads and boots (Fig. $7. (2) Press pistons, cups and. spring and expender ut of jlnder bore (3) Remave bie serew 6 Verne Fig. 57 Whee! Cynder Components-Typeal CLEANING Mido brake cleaner only. Do not use any other ‘leaning agents Dry the linger and pistons with compressed a Do not use rags ar shop towels to dry the eyinder Connponenns. Lit from lh material will adhere the lider bores and sts, INSPECTION Inspect the cylinder bore, Light disor ark stains in the bore are “The elindes bore ca be lightly polished but nly with eros dah Replace the cinder i the bare ‘oved, pitted or healy corroded Honing the bor to restore the surface fs mot recommended. spect the finer pstans ‘The piston surfaces shuld be south and free of scratches, scoring aedw WHEEL CYLINDERS (Continued) ‘corrosion, Replace the pstons if wor, sored, oF cor raded. Do attempt to restore the surface by sanding Discard the old piston cups an the spring and cexpanier: These parts are nat reusable The original [ASSEMBLY (0) Labrcate whee! cinder bore pistons, piston {2 towall rst _piston in eylinder bore. Then Install fst cup in bre aid agate piston. Be sure Up. of pion cup te facing Inward: (oward spring Sid expander) and flat aide is apainat isto (3 Tall ring, ar expander lone (anata oot an each end of ner a eset push rds Boots, (Install inde eed sere INSTALLATION (1) Apply bead of scone seater around cytinder ang are sgt pte mer es) stall bake line to esinder and ghten to 16 Naw (12 ths), all brake dra, all lee and tre asserbly (Refer wo 22 DURE, (7) Bed base brake system. (Refer 5 - BRAKES, STANDARD PROCEDURE SUPPORT PLATE REMOVAL (Q) Rermave wheel and tire assembly (2) Reve the disc brake caliper Refer to 5 BRAKESIHYDRAULICMECHANICALDDISC (G) Remove the rotor (Fig. S8\Refer wo 5 BRAKESIHYDRAULICI MECHANICAL ROTORS REMOVAL) 1W) Renene the axle shat (Fig. SO\Reter to 3 AXLE SHAFTS | REMOVAL} (©) Remove the park brake shoes (Fig. 59) Refer to'5 BRAKESIPARKING BRAKE'SHOES - REMOV. AD, (© Remove the parking brake cable from the brake lever. Fig. 58 PARK BRAKE SHOES INSTALLED Fig, 59 BRAKE SHOES (7) Remove the bats attaching the suppor plate to the ante and remese the support pate INSTALLATION (0 Install support plate on axle lange. Tighten attaching bots fe 115 Bim (83 fe Ibs)5-34 BRAKES - BASE ‘SUPPORT PLATE (Continued) (2) Install the pork brake shoes (Fg 59) (eer to 5 DRAKESPARKING BRAKESHOES » INSTALLS TION, (3) lnstll parking brake cable fn the brake lever (4) stall ele shaft Fig, 58) Refer to 3- DIF FERENTIAL, & DRIVELINE/REAR ANTE.» AXLE SHAFTS INSTALLATION. (G) Adjat brake shoes t drum with brake gauge (Reler to 3 BRAKPSIPARKING BRAKESHOES ADJUSTMENTS} (6) Intall the rotor (Refer to 5 ~ BRAKESIHY. DRAULICMECHANICALIROTORS. — INSTALL TION (7) intl the callper (Refer to 5.» BRAKESIHY: INSTALLATION). (8) Install the whee an tre assembly (Refer to 22 DURE PARKING BRAKE DESCRIPTION “The parking bake i @ hand lever and cable oper ate syate une #9 apy the tee Brakes. OPERATION 'A hand operated lever in the passenger compart Sioner The tesioner eid a attached tothe equaier ‘whieh i the connecting point or te rear cables Fg Fig 60 Parking Bako Components 1 ‘The rear cables are connected to the actuating lever on each secondary brake shoe: The levers are {ita or welded tothe lever A ip ia ued ta secure the pin in the brake shaw The pin allan each lever "To apply the parking brakes, the hand lever is pulled upward. This pulls the rear brake shoe sce ‘ing levers forward, by means tensioner and cables As the actuating lover f plled forward che parking ‘rake strat (which Is erste Bothy shoes exerts 2 linear force against the primary brake shoe This ‘ction presses the primary shoe Into contact with the ‘rum. ‘Once the primary shoe cancacts the drum Tevved throug che strut wo Une secndary brake shoe ‘using It pivot Into the erm as el fee ace ra a el felease I acamplised by the hat ever release tut ‘A parking brake switch is mounted an the parking lever, The switch, which isin crcut with the yd ‘warning igh inthe dash, wll Marinate the warn Ing light whenever the parking brakes ae ape Parking broke adjustment controlled by a cable tensioner mechanism. ‘The ‘cable tensioner ance ‘ajusted at the Tactory, should ot need Taner ‘astment under normal cleumstances. Adjustment installed. oe disconnected DIAGNOSIS AND TESTING - PARKING BRAKE NOTE: Parking brake adjustment Is controled by a Ccbla tensioner Once the tensioner Ie adjusted at the facor, It should not requir further atfontion However, thee are to instances when adjustment Wil be required. The tests when a new tension Dr cables have boon installed. And the second fe ‘when the tensioner and cables are disconnected for ‘ecers to sther brake components: ‘The parking brake site isi erat withthe eed ‘warning amp inthe dash The swith wil cause the Von ta uminate only wine the porn rakes sre fpplied Ifthe lamp renin on afer parking brake felease, the stich or wives ore faulty or cable et Sonor adjustment is correct Tm most cases, the actual cause of an improperly fuesaning, parking. brake (oo acelin Ugh hal) can be vaced 1 9 parking brake companent “The leading cause of tnproper parking brake oper ation, extesive clearance beaneen the parking fale abocs red the shoo braking surface’ Exess dearance Is a result of lining andi rum wearw PARKING BRAKE (Continued) ‘drum surface machined oversize, oF inoperative ‘sdhntr components, ceive parking brake lever eavel Gometnes the result of morn brake sles, eaprper brake shoe will most probly be due to a whee! brake campo Heme to look for when dlgnosing a parking brake Rear brake shoe weer. 1 Drumm surface machined oversize 1 Fron cable not secured to lever, 1 Rear cable seized 1 Brake snes reverse 1 Parking brake strat not seated in shar Parking brake lever tot seated Parking brake iver bind Agjuster serows sized, { Aajsterserews reversed, procedures are described in the Parking Brake see SHOES DESCRIPTION expanding unite wih an eutomatie self ejusting ‘mechan (ia, ‘OPERATION ‘When the parking brake peal 1s depressed the brake cable pulls the brake shoes outward aglnst the brake drum. When the brake peal y released the return speings attached tothe brake shes pall the shoes back to there rginal position, REMOVAL (A) Raise and supp he vehi (2) Rermove the tie and heel assembly (5) Remove the dsc brake caliper, (Fig 62\(Refer to' 3 ~ BRAKESIYDRAULICMECHANICAL/DISC BRAKE CALIPERS - REMOVAL) 1M) Remnve the dae brake rotor, (Fig 62Refer to 5 0 BRAKESHYDRAULICMECHANICAL ROTORS. REMOVAL, (@) Disassemble the rear park brake shoes (Fig 6. BRAKES - BASE 5-35 Fig. 61 BRAKE SHOESFig, 68 BRAKE SHOES CLEANING - REAR DRUM IN HAT BRAKE lau cr wih brake cater Do et ust any ar ‘leoning egens. Remave light rust and scale from thei cat pach oth sere INSPECTION - REAR DRUM IN HAT BRAKE ‘As general re, riveted broke shoes should be replace when ur whin O78 sam (082 Hn) of the iver heads. Bonded lining should be replaced ‘when worn toa thickness of 1.6 am (V/16 the shoes are hen or the dusts tapered The ig, Should exh contact across its entire widkh, Shoes fxhibiing contact only. one side" shouldbe (Fie 60, Tispect the adjuster screw assembly. Replace the ‘assembly ifthe star wheel or threads are damaged, (hig Discard the brake springs and retainer components ie worn, distort or collapsed. Also replace the fprings if a brake drag condition had ercured. Over. 1 pect the brake se contact pads on the suppor. plate replace the support pate if any af the pads are ent or dintrced (Fi. 68) Fig. 64 BRAKE SHOES INSTALLATION pavement or concrete uting light to moderate force ‘nthe parking brake lever (0) Reassemble the rear park take shes (Fg. 63) (2) Adjust the rear brake shoes (Roler to 5 BRAKESIPARKING BRAKEISHOES ADJUST: MENTS) (3) Install the dise brake rotor Refer wo 5 DBRAKESIMYDRAULICIMECHANICA/ROTORS INSTALLATION). (a) stall the dine brake caliper (Refer ta § BRAKES/HYDRAUILICMECHANICALIDISC, BRAKE CALIPERS - INSTALLATION) (5) Install the tire are wheel assembly [Refer to 22 TIRESWHEELSIWHEELS - STANDARD PROCE. DURE). (6) Lover the vehiclew SHOES (Continued) ADJUSTMENTS [ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED) rent ie required is when the shes are replaced, Femowel for acess 10 ter parts. ar whet one oF “Adjustment canbe mede with 9 standard brake auger with adjusting wel, Adjustment i per formed with the complete brake sembly installed ‘CAUTION: Bofore adjusting the park brake shoes be ‘sure that the park brake pedal is in tho fully Feleased position. Hf park brake pedal is notin the {ly teleasea positon, the park brake shoes can not be accurately adjusted (4) Raise vehicle (2) Rem tee aed whee (5) Remove dis brake caliper fom caliper adapter (Refer '5 - BRAKESHYDRAULICIMECHANICAL/ DISC BRAKE CALIPERS - REMOVAL) 1G) Remoe rotor frm the axleshofe [Refer to 5 REMOVAL), NOTE: When me the dismater should be measured inthe centor of ‘the area in which the park brake shoos contact the ‘surface of the brake drum, (9) Using Brake Shor Gauge. Special Tol C919, cer equivalent, accurately messure the inside dim ter of the park brake drut partion of the rotor (Fh oo) ‘lg. 65 MEASURING PARK BRAKE DRUM DAMETER BRAKES - BASE 5-37 (6) Using @ rater that reads in 6th of an inch, ‘ccuratety reed the measurement of the Inside dam ig. 66, Fig, 66 READING PARK BRAKE DRUM DIAMETER (7) Reduce the inskle diameter measurement. of the brake drum that was taken using Spal. Tol {C5518 by Mi ofan inchs Reset Gauge Brake Show Special Tool C3010 oe the equivalent usd, so that the autse measure rear (0) ss are sec the reduced Fig 67 SETTING GAUGE TO PARK BRAKE SHOE MEASUREMENT (6) Place Gauge, Brake Shue, Spcal Toa C3919, cr equivalent aver the park brake shoes. The special tool mast be located laponalty across at the top of Se thon tan we oe det pt