Dodge Brakes SRM 2006 Service Manual

DR BRAKES 5 - 1

BRAKES

TABLE OF CONTENTS

page page

BRAKES - BASE - SERVICE INFORMATION...... 1

BRAKES - ABS ELECTRICAL DIAGNOSTICS

EBC 125 RWAL ........................ 104

BRAKES - BASE - SERVICE INFORMATION

TABLE OF CONTENTS

page page

BRAKES - BASE - SERVICE INFORMATION

DIAGNOSIS AND TESTING

BASE BRAKE SYSTEM .......................3

STANDARD PROCEDURE

MANUAL BLEEDING .........................6

PRESSURE BLEEDING .......................6

SPECIAL TOOLS

BASE BRAKES ..............................6

SWITCH-ADJUSTABLE PEDALS

REMOVAL .....................................8

INSTALLATION ................................8

MOTOR-ADJUSTABLE PEDALS

DESCRIPTION .................................9

REMOVAL .....................................9

INSTALLATION ...............................10

HYDRAULIC/MECHANICAL

SPECIFICATIONS

BASE BRAKE ...............................11

TORQUE ...................................13

LINES-BRAKE

STANDARD PROCEDURE

DOUBLE INVERTED FLARING ...............15

ISO FLARING ...............................15

REMOVAL

REAR BRAKE HOSE ........................16

REAR TUBE / HOSE ASSEMBLY .............16

FRONT BRAKE HOSE .......................17

INSTALLATION

REAR BRAKE HOSE ........................17

REAR TUBE / HOSE ASSEMBLY .............18

FRONT BRAKE HOSE .......................18

PADS - BRAKE

REMOVAL

LD .........................................19

HD ........................................20

BRAKES - ABS ELECTRICAL DIAGNOSTICS

EBC 340 AWAL ........................ 164

BRAKES - ABS - SERVICE INFORMATION..... 271

SRT10 .....................................22

REAR ......................................23

INSTALLATION

LD .........................................25

HD ........................................26

SRT10 .....................................28

REAR ......................................29

CALIPERS-DISC BRAKE

DESCRIPTION

LIGHT DUTY (LD) CALIPERS ................32

HEAVY DUTY (HD) CALIPERS ...............32

FRONT CALIPERS – SRT10 .................32

OPERATION

DISC BRAKE CALIPER ......................33

REMOVAL

FRONT - LD ................................34

FRONT - HD ................................35

FRONT - SRT10 ............................36

REAR ......................................36

REAR-SRT10..............................37

DISASSEMBLY

LD .........................................37

HD ........................................39

FRONT - SRT10 ............................41

INSPECTION – (HD) ..........................46

ASSEMBLY

LD .........................................46

HD ........................................48

SRT10 .....................................48

INSTALLATION

FRONT – LD ...............................50

FRONT - HD ................................51

FRONT - SRT10 ............................52

REAR ......................................52

REAR-SRT10..............................53

5 - 2 BRAKES - BASE - SERVICE INFORMATION DR

ADAPTER-DISC BRAKE CALIPER

REMOVAL

FRONT ....................................54

REAR ......................................55

INSTALLATION

FRONT ....................................56

REAR ......................................58

MOUNT-DISC BRAKE CALIPER ADAPTER

REMOVAL

REAR ......................................59

INSTALLATION ...............................59

FLUID

DESCRIPTION

BRAKE FLUID ..............................61

DIAGNOSIS AND TESTING

BRAKE FLUID CONTAMINATION .............61

STANDARD PROCEDURE

BRAKE FLUID LEVEL .......................61

RESERVOIR-FLUID

REMOVAL ....................................62

INSTALLATION ...............................62

BRAKE JUNCTION BLOCK

REMOVAL ....................................63

INSTALLATION ...............................63

MASTER CYLINDER

DESCRIPTION ................................64

OPERATION ..................................64

DIAGNOSIS AND TESTING

MASTER CYLINDER/POWER BOOSTER ......64

STANDARD PROCEDURE

MASTER CYLINDER BLEEDING .............66

REMOVAL

ALL EXCEPT HYDROBOOST ................66

HYDROBOOST .............................67

INSTALLATION

ALL EXCEPT HYDROBOOST ................67

HYDROBOOST .............................68

PEDAL

DESCRIPTION ................................69

OPERATION ..................................69

REMOVAL ....................................69

INSTALLATION ...............................70

BOOSTER-POWER BRAKE

DESCRIPTION ................................72

OPERATION ..................................72

REMOVAL ....................................72

INSTALLATION ...............................73

BOOSTER-HYDRO-BOOST BRAKE

DIAGNOSIS AND TESTING

HYDRAULIC BOOSTER .....................74

STANDARD PROCEDURE

BLEEDING .................................75

REMOVAL ....................................76

INSTALLATION ...............................76

ROTORS

DIAGNOSIS AND TESTING

DISC BRAKE ROTOR .......................78

REMOVAL

FRONT – LD ...............................79

FRONT – HD ...............................79

REAR ......................................80

REAR DUAL WHEELS .......................80

INSTALLATION

FRONT – LD ...............................81

FRONT – HD ...............................81

REAR ......................................81

REAR DUAL WHEELS .......................82

PLATE-SUPPORT

REMOVAL ....................................83

INSTALLATION ...............................83

DUCTS-BRAKE COOLING - SRT10

REMOVAL ....................................85

INSTALLATION ...............................87

PARKING BRAKE

DESCRIPTION ................................89

OPERATION ..................................89

CABLES

REMOVAL

FRONT PARKING BRAKE CABLE ............90

REAR PARK BRAKE CABLE .................91

RIGHT REAR CABLE ........................91

LEFT REAR CABLE .........................92

INSTALLATION

FRONT PARKING BRAKE CABLE ............93

REAR PARK BRAKE CABLE .................93

RIGHT REAR CABLE ........................94

LEFT REAR CABLE .........................94

SHOES

REMOVAL ....................................95

CLEANING - REAR DRUM IN HAT BRAKE ......96

INSPECTION - REAR DRUM IN HAT BRAKE ....96

INSTALLATION ...............................96

ADJUSTMENTS

PARKING BRAKE SHOES ...................97

WITH ADJUSTING TOOL ....................99

PEDAL

REMOVAL ...................................100

INSTALLATION ..............................100

TENSIONER-CABLE

ADJUSTMENTS

CABLE TENSIONER .......................101

HANDLE-RELEASE

REMOVAL ...................................102

INSTALLATION ..............................103

DR BRAKES - BASE - SERVICE INFORMATION 5 - 3

BRAKES - BASE - SERVICE INFORMATION

DIAGNOSIS AND TESTING BASE BRAKE SYSTEM

Base brake components consist of the brake pads, calipers, brake drum in hat rotor in the rear, rotors, brake lines, master cylinder, booster, and parking brake components.

Brake diagnosis involves determining if the problem is related to a mechanical, hydraulic, or vacuum operated component.

The first diagnosis step is the preliminary check.

PRELIMINARY BRAKE CHECK

1. Check condition of tires and wheels. Damaged wheels and worn, damaged, or underinflated tires can cause pull, shudder, vibration, and a condition 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 fluid level will decrease in proportion to normal lining 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, wheel cylinders, brake lines, and master

cylinder.

b. If fluid appears contaminated, drain out a sample to examine. System will have to be flushed if fluid is sep-

arated into layers, or contains a substance other than brake fluid. The system seals and cups 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 pedal. 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 or for bind condition. 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.

ROAD TESTING

1. 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 and note grab, drag, noise, etc.

PEDAL FALLS AWAY

A brake pedal that falls away under steady foot pressure is generally the result of a system leak or fluid contamination. The leak point could be at a brake line, fitting, hose, or caliper/wheel cylinder. 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 or RWAL system may also be the problem with no physical evidence.

LOW PEDAL

If a low pedal is experienced, pump the pedal several times. If the pedal comes back up worn linings, rotors, drums, or rear brakes out of adjustment are the most likely causes. The proper course of action is to inspect and replace all worn component and make the proper adjustments.

5 - 4 BRAKES - BASE - SERVICE INFORMATION DR

SPONGY PEDAL

A spongy pedal is most often caused by air in the system. However, thin brake drums or substandard brake lines and hoses can also cause a spongy pedal. The proper course of action is to bleed the system, and replace thin drums and substandard quality brake hoses if suspected.

HARD PEDAL OR HIGH PEDAL EFFORT

A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or badly worn. The power booster or check valve or a vacuum hose could also be faulty.

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, or out of

round brake drums. Other causes are loose wheel bearings or calipers and worn, damaged tires.

NOTE: Some pedal pulsation may be felt during ABS activation.

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 shoe release. Drag can be minor or severe enough to overheat the linings, rotors and drums.

Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in rotors and drums from the overheat-cool down process. In most cases, the rotors, drums, wheels and tires are quite warm to the touch after the vehicle is stopped.

Severe drag can char the brake lining all the way through. It can also distort and score rotors and drums 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:

• Seized or improperly adjusted parking brake cables.

• Loose/worn wheel bearing.

• Seized caliper or wheel cylinder piston.

• Caliper binding on corroded bushings or rusted slide surfaces.

• Loose caliper mounting.

• Drum brake shoes binding on worn/damaged support plates.

• Mis-assembled components.

• Long booster output rod.

If brake drag occurs at all wheels, the problem may be related to a blocked master cylinder return port, or faulty power booster (binds-does not release).

BRAKE FADE

Brake fade is usually a 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 the Brake Drag information in this section for causes.

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

DR BRAKES - BASE - SERVICE INFORMATION 5 - 5

• Improper brake pads

• Damaged rotor

A worn, damaged wheel bearing or suspension component are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull.

A 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).

REAR BRAKE GRAB OR PULL

Rear grab or pull is usually caused by improperly adjusted or seized parking brake cables, contaminated lining, bent or binding shoes and support plates, 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 proportioning valve could be at fault.

BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES

This condition is generally caused by water soaked lining. If the lining is only wet, it can be dried by driving with the brakes very lightly applied for a mile or two. However, if the lining is both soaked and dirt contaminated, cleaning and/or replacement will be necessary.

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.

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. Severely worn tires with very little tread left 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. A tire with internal damage such as a severe bruise, cut, or ply separation can cause pull and vibration.

BRAKE NOISES

Some brake noise is common with rear drum brakes and 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.

BRAKE SQUEAK/SQUEAL

Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oil. Glazed linings and rotors with hard spots can also contribute to squeak. Dirt and foreign material embedded in the brake lining will also cause squeak/squeal.

A very loud squeak or squeal is frequently a sign of severely worn brake lining. If the lining has worn through to the brake pads in spots, metal-to-metal contact occurs. If the condition is allowed to continue, rotors can become so scored that replacement is necessary.

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.

5 - 6 BRAKES - BASE - SERVICE INFORMATION DR

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. However, calipers that bind on the slide surfaces can generate a thump or clunk noise.

STANDARD PROCEDURE MANUAL 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.

1. Remove reservoir filler caps and fill reservoir.

2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding.

3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid.

NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front.

4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel.

5. Before moving the vehicle verify the pedal is firm and not mushy.

6. Top off the brake fluid and install the reservoir cap.

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.

Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding.

Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing

air back into the system.

SPECIAL TOOLS BASE BRAKES

INSTALLER, BRAKE CALIPER DUST BOOT C-4340

DR BRAKES - BASE - SERVICE INFORMATION 5 - 7

INSTALLER, BRAKE CALIPER DUST BOOT

C-3716-A

HANDLE C-4171

CAP, MASTER CYLINDER PRESSURE BLEED 6921

GAUGE, BRAKE SAFE-SET C-3919

5 - 8 BRAKES - BASE - SERVICE INFORMATION DR

SWITCH-ADJUSTABLE PEDALS

REMOVAL

1. Remove the lower drivers side bezel (4) (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL DR SIDE BEZEL - REMOVAL).

2. Disconnect the electrical connector (3) from the adjustable pedal switch (2).

3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards.

INSTALLATION

1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4).

2. Reconnect the electrical connector (3) to the adjustable pedal switch (2).

3. Install the lower drivers side bezel (4) (Refer to 23

- BODY/INSTRUMENT PANEL/INSTRUMENT PANEL DR SIDE BEZEL - INSTALLATION).

DR BRAKES - BASE - SERVICE INFORMATION 5 - 9

MOTOR-ADJUSTABLE PEDALS

DESCRIPTION

The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals.

Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable.

The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator

application.

• SYSTEM FEATURES:

• Range of Adjustment: The pedals may be adjusted up to 3 in. (75 mm)

• Pedal Adjustment Speed: 0.5 in./sec (12.5 mm/sec)

• Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when

cruise control is activated.

REMOVAL

1. Disconnect the negative battery cable.

2. Remove the kneeblocker (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER REMOVAL).

3. Remove the brake light switch and discard (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).

4. Disconnect the adjustable pedal cables from the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission.

5. Disconnect the electrical connector.

6. Unclip the cable fasteners to the support.

7. Remove the one mounting bolt (2) for the adjustable pedal motor (1).

8. Remove the adjustable pedal motor (1) with the cables.

NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed.

5 - 10 BRAKES - BASE - SERVICE INFORMATION DR

INSTALLATION

NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed.

1. Install the adjustable pedal motor (1) with the cables.

2. Install the one mounting bolt (2) for the adjustable pedal motor (1).

3. Clip the cable fasteners to the support.

4. Reconnect the electrical connector.

5. Reconnect the adjustable pedal cables to the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission.

6. Install the new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).

7. Install the kneeblocker (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER INSTALLATION).

8. Reconnect the negative battery cable.

9. Check for proper operation of the pedals.

DR BRAKES - BASE - SERVICE INFORMATION 5 - 11

HYDRAULIC/MECHANICAL

SPECIFICATIONS BASE BRAKE

SPECIFICATIONS

DESCRIPTION SPECIFICATION

Front Disc Brake Caliper

Type

Rear Disc Brake Caliper

Type

Rear Disc Brake Caliper

Type

SRT-10

Rear Disc Brake Caliper

Type

Front Disc Brake Caliper

SRT-10

Front Disc Brake Caliper

Front Disc Brake Rotor

SRT-10

Front Disc Brake Rotor

Front/Rear Disc Brake Rotor

Max. Runout

Front Disc Brake Rotor

Max. Runout

SRT-10

Rear Disc Brake Rotor

Max. Runout

SRT-10

Front/Rear Disc Brake Rotor

Max. Runout

SRW

Rear Disc Brake Rotor

Max. Runout

DRW

Front/Rear Disc Brake Rotor

Max. Thickness Variation

Dual Piston Sliding

Single Piston Sliding

Dual Piston Sliding

2X54 mm (2.12 in.)

4X57 mm (2.24 in.)

2X56 mm (2.20 in.)

336×28 mm (13.2×1.1 in.)

380×35.5 mm (14.96×1.397 in.)

353×35.5 mm (13.89×1.397 in.)

0.050 mm (0.002 in.)

0.131 mm (0.005 in.)

0.328 mm (0.012 in.)

0.012 mm (0.0005 in.)

5 - 12 BRAKES - BASE - SERVICE INFORMATION DR

DESCRIPTION SPECIFICATION

Front Disc Brake Rotor

Max. Thickness Variation

SRT-10

Rear Disc Brake Rotor

Max. Thickness Variation

SRT-10

Front/Rear Disc Brake Rotor

Max. Thickness Variation

Minimum Front Rotor Thickness

SRT-10

Minimum Front Rotor Thickness

Mininium Rear Rotor Thickness

SRT-10

Rear Disc Brake Caliper

SRT-10

Rear Disc Brake Caliper

SRW

Rear Disc Brake Caliper

DRW

Rear Disc Brake Rotor

SRT-10

Rear Disc Brake Rotor

Max Drum Diameter

SRT-10 & HD

Brake Booster

Type

Gasoline Engines

Brake Booster

Type

Gasoline Engines

SRW

0.012 mm (0.0005 in.)

0.013 mm (0.0005 in.) Loose Rotor

26.4 mm (1.039 in.)

33.9 mm (1.344 in.)

34 mm (1.33 in.)

20.4 mm (.803 in)

28.39 mm (1.117 in)

28.4 mm (1.118 in.)

1x54 mm (2.12 in)

2x36 mm (1.42 in)

2x45 mm (1.77 in)

2x51 mm (2.00 in)

350x22 mm (13.77 X .86 in)

353x30 mm (13.89 X 1.18 in)

207.2 mm (8.157 in.)

Vacuum Dual Diaphragm

DR BRAKES - BASE - SERVICE INFORMATION 5 - 13

DESCRIPTION SPECIFICATION

Brake Booster

Type

Diesel Engines

DRW

Hydroboost

TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Brake Booster

Mounting Nuts

Master Cylinder

Mounting Nuts

Caliper Bleed Screws 19 14 168

Caliper

Mounting Pins

Front

Caliper

Mounting

Front

SRT10

Disc Brake Pad

Hold down

Center bolt

SRT10 Caliper

Mounting Pins

Rear

Caliper

Adapter Mounting Bolts

Front

Caliper

Adapter Mounting Bolts

Front

Caliper

Adapter Mounting Bolts

Rear

Caliper

Adapter Mounting Bolts

Rear

SRT10

Junction Block

Bolts To Frame

Brake Pedal Assembly

Bracket

Nuts

28 21 250

18 — 160

32 24 —

176 130 —

115 85 —

30 22 —

176 130 —

339 250 —

135 100 —

197 145 —

10 7.5 —

28 21 —

5 - 14 BRAKES - BASE - SERVICE INFORMATION DR

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Support Plate

Mounting Bolts/Nuts

Support Plate

Mounting Bolts/Nuts

SRT-10 & HD

Brake Line Fittings

Master Cylinder

Brake Line Fittings

Junction Block

Caliper

Brake Line Banjo Bolt

Front

Caliper

Brake Line Banjo Bolt

Rear

Brake Hose

Front Bolts To Frame

Brake Hose Front Fitting

Brake Hose Rear Fitting

Parking Brake Pedal

Assembly

Rotor to Hub Bolt

Rear

HD DRW

Extension to Rotor Nut

HD DRW

Front

Hub/Bearing

Bolts

SRT10

Hub/Bearing

Bolts

Front 4X2 HD

64 47 —

203 150 —

19 14 170

27 20 245

10 7.5 —

19 14 250

128 95 —

130 96 —

163 120 —

176 130 —

DR BRAKES - BASE - SERVICE INFORMATION 5 - 15

LINES-BRAKE

STANDARD PROCEDURE DOUBLE INVERTED FLARING

A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available.

1. Cut off damaged tube with Tubing Cutter.

2. Ream cut edges of tubing to ensure proper flare.

3. Install replacement tube nut on the tube.

4. Insert tube in flaring tool.

5. Place gauge form over the end of the tube.

6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter.

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.

ISO FLARING

A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available.

To make a ISO flare use an ISO flaring tool kit.

1. Cut off damaged tube with Tubing Cutter.

2. Remove any burrs from the inside of the tube.

3. Install tube nut on the tube.

4. Position the tube in the flaring tool flush with the top of the tool bar (6). Then tighten the tool bar on the tube.

5. Install the correct size adaptor (1) on the flaring tool yoke screw.

6. Lubricate the adaptor (2).

7. Align the adaptor and yoke screw over the tube.

8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar.

5 - 16 BRAKES - BASE - SERVICE INFORMATION DR

REMOVAL REAR BRAKE HOSE

1. Raise and support the vehicle.

2. Remove the brake line (3) from the hose (1) at the frame.

3. Remove the brake hose clip (2) at the top of the hose located at the frame.

4. Remove the vent hose (2).

5. Remove the two brake lines (3) at the bottom of the hose (1) located at the axle.

6. Remove the mounting bolt for the brake hose at the axle.

7. Remove the hose.

REAR TUBE / HOSE ASSEMBLY

1. Raise and support the vehicle.

2. Remove the brake line located at the axle.

3. Remove the mounting bolt (2) for the brake hose (3) at the axle.

4. Remove the banjo bolt (1) at the caliper.

5. Remove the hose.

DR BRAKES - BASE - SERVICE INFORMATION 5 - 17

FRONT BRAKE HOSE

1. Raise and support vehicle.

2. Remove the tire and wheel assembly.

3. Remove the brake hose (2) from the brake line located at the frame.

4. Remove the brake hose banjo bolt (3) at the caliper.

5. Remove the mounting bolt securing the brake hose (2) to the frame and remove the wheel speed sensor wire (4) from the brake hose (2).

6. Remove the hose.

INSTALLATION REAR BRAKE HOSE

1. Install the hose (1).

2. Install the mounting bolt for the brake hose (1) at the axle.

3. Install the two brake lines (3) at the bottom of the hose located at the axle.

4. Install the vent hose (2).

5. Install the brake hose clip (2) at the top of the hose (1) located at the frame.

6. Install the brake line (3) to the hose at the frame.

7. Lower the vehicle and remove the support.

8. Bleed the brake system (Refer to 5 - BRAKES STANDARD PROCEDURE).

5 - 18 BRAKES - BASE - SERVICE INFORMATION DR

REAR TUBE / HOSE ASSEMBLY

1. Install the hose (3).

2. Install the banjo bolt (1) at the caliper and tighten fitting bolt to 27 N·m (245 in. lbs.).

3. Install the mounting bolt (2) for the brake hose (3) at the axle.

4. Install the brake line located at the axle.

5. Lower the vehicle and remove the support.

6. Bleed the brake system (Refer to 5 - BRAKES STANDARD PROCEDURE).

FRONT BRAKE HOSE

1. Install the hose (3).

2. Install the mounting bolt (1) for the brake hose (3) at the frame.

3. Install the brake hose banjo bolt at the caliper.

4. Reinstall the wheel speed sensor wire (2) to the brake hose.

5. Remove the support and lower the vehicle.

6. Bleed the brake system (Refer to 5 - BRAKES STANDARD PROCEDURE).

DR BRAKES - BASE - SERVICE INFORMATION 5 - 19

PADS - BRAKE

REMOVAL LD

1. Raise and support vehicle.

2. Remove the wheel and tire assemblies.

3. Compress the caliper (2).

4. Remove the caliper slide pin bolts (4), (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).

5. Remove the caliper (1) from the caliper adapter (2).

NOTE: Do not allow brake hose to support caliper assembly.

6. Support and hang the caliper.

5 - 20 BRAKES - BASE - SERVICE INFORMATION DR

7. Remove the inboard brake pad (4) from the caliper adapter (1).

8. Remove the outboard brake pad (2) from the caliper adapter (1).

9. Remove the anti-rattle clips (1) from the pad (2).

1. Raise and support vehicle.

2. Remove the wheel and tire assemblies.

3. Compress the caliper.

4. Remove the caliper, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).

5. Remove the caliper by tilting the top up and off the caliper adapter.

NOTE: Do not allow brake hose to support caliper assembly.

6. Support and hang the caliper.

DR BRAKES - BASE - SERVICE INFORMATION 5 - 21

7. Remove the inboard brake shoe (1) from the caliper adapter (2).

8. Remove the outboard brake shoe (1) from the caliper adapter (2).

NOTE: Anti-rattle springs are not interchangeable.

9. Remove the top anti-rattle springs (2) from the caliper adapter (1).

5 - 22 BRAKES - BASE - SERVICE INFORMATION DR

10. Remove the bottom anti-rattle springs (2) from the

caliper adapter (1).

SRT10

1. Remove the tire and wheel assembly.

2. Remove the pad center hold down bolt (4) from the caliper (1).

3. Remove the bolt sleeve (3) and the hold down springs (2).

4. Carefully push the caliper pistons back in order to get the pads out.

5. Remove the inboard and outboard disc brake pads (2) from the caliper (1).

6. Carefully push each piston to the bottom of the bore.

DR BRAKES - BASE - SERVICE INFORMATION 5 - 23

REAR

1. Raise and support the vehicle.

2. Remove the rear wheel and tire assemblies.

3. Compress the caliper.

4. Remove caliper slide bolts (3).

NOTE: Do not allow brake hose to support caliper assembly.

5. Remove the caliper (3), (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS

- REMOVAL) and then tilt the top up and off the caliper adapter.

6. Remove inboard brake shoe (1) from the caliper adapter (2).

5 - 24 BRAKES - BASE - SERVICE INFORMATION DR

7. Remove outboard brake shoe (1) from caliper adapter (2).

NOTE: Anti-rattle springs are not interchangeable.

8. Remove the top anti-rattle spring (2) from the caliper adapter (1).

9. Remove the top anti-rattle spring (2) from the caliper adapter (1).

DR BRAKES - BASE - SERVICE INFORMATION 5 - 25

INSTALLATION LD

1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston.

2. Clean caliper mounting adapter.

3. Install new anti-rattle clips (1) to the brake pads (2).

4. Install inboard brake pad (4) in adapter (1).

5. Install outboard brake pad (2) in adapter (1).

5 - 26 BRAKES - BASE - SERVICE INFORMATION DR

6. Install the caliper (1) over rotor, Then push the caliper onto the adapter (2).

7. Install caliper slide pin bolts (4), (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).

8. Install wheel and tire assemblies and lower vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).

9. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal.

10. Top off master cylinder fluid level.

1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston.

2. Clean caliper mounting adapter (1) and anti-rattle springs (2).

3. Lubricate anti-rattle springs with Mopar brake grease.

NOTE: Anti-rattle springs are not interchangeable.

4. Install new top anti-rattle springs (2).

DR BRAKES - BASE - SERVICE INFORMATION 5 - 27

5. Install new bottom anti-rattle springs (1).

6. Install inboard brake shoe (1) in adapter (2).

5 - 28 BRAKES - BASE - SERVICE INFORMATION DR

7. Install outboard brake shoe (1) in adapter (2).

8. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter.

9. Install caliper, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).

10. Install wheel and tire assemblies and lower vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD

PROCEDURE).

11. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal.

12. Top off master cylinder fluid level.

SRT10

1. Install the new disc brake pads (2) into the caliper (1). Ensure each pad is properly seated in the

caliper.

DR BRAKES - BASE - SERVICE INFORMATION 5 - 29

2. Install the pad hold down spring (2) and sleeve (3).

3. Install the disc brake pad hold down bolt (4).

4. Tighten the disc brake pad center mounting bolt (4) to 115 N·m (85 ft.lbs.).

5. Install the tire and wheel assembly.

REAR

1. Clean caliper mounting adapter (1) and anti-rattle springs (2).

2. Lubricate anti-rattle springs with Mopar brake grease.

NOTE: Anti-rattle springs are not interchangeable.

3. Install new top anti-rattle spring (2).

5 - 30 BRAKES - BASE - SERVICE INFORMATION DR

4. Install new bottom anti-rattle spring (1).

5. Install inboard brake shoe (1) in adapter (2).

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