Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Dakota 2000-2001.2003.2005 Approved Dodge Dakota 2000 00AN_5
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AN BRAKES 5-1
BRAKES
TABLE OF CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 FOUR WHEEL ANTILOCK BRAKES. . . . . . . . . . . . 40
REAR WHEEL ANTILOCK BRAKES . . . . . . . . . . . . 32
BASE BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 14
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 15
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 16
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3 DISC BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . . 17
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 3 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3 REAR BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . 19
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 3 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 21
DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . . 21
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5 PARK BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . 22
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . . 5 REAR PARK BRAKE CABLES . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 5 MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 23
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 8 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 24
MASTER CYLINDER/POWER BOOSTER . . . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 25
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 8 CLEANING AND INSPECTION
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . 9 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 27
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 10 ADJUSTMENTS
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 10 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE PROCEDURES PARK BRAKE CABLE TENSIONER . . . . . . . . . . . 29
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS
BRAKE FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . 11 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . . 12 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 12 SPECIAL TOOLS
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 12 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13
5-2 BRAKES AN
DESCRIPTION AND OPERATION cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
BRAKE SYSTEM oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
DESCRIPTION and flush the system with new brake fluid if con-
This vehicle is equipped with front disc brakes and tamination is suspected.
rear drum brakes. The front disc brakes consist of
single piston calipers and ventilated rotors. The rear CAUTION: Use Mopar brake fluid, or an equivalent
brakes are dual brake shoe, internal expanding units quality fluid meeting SAE/DOT standards J1703 and
with cast brake drums. The parking brake mecha- DOT 3. Brake fluid must be clean and free of con-
nism is cable operated and connected to the rear taminants. Use fresh fluid from sealed containers
brake secondary shoes. Power brake assist is stan- only to ensure proper antilock component opera-
dard equipment. A vacuum operated power brake tion.
booster is used for all applications.
Two antilock brake systems are used on this vehi-
cle. A rear wheel antilock (RWAL) brake system is CAUTION: Use Mopar multi-mileage or high temper-
standard. An all-wheel antilock brake system (ABS) ature grease to lubricate caliper slide surfaces,
is available as an option. drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
SERVICE WARNINGS & CAUTIONS 661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PEDAL
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR DESCRIPTION
AFTERMARKET LININGS. BREATHING EXCESSIVE A suspended-type brake pedal is used. The pedal is
CONCENTRATIONS OF ASBESTOS FIBERS CAN attached to the pedal support bracket with a pivot
CAUSE SERIOUS BODILY HARM. EXERCISE CARE bolt and bushings. The booster push rod is attached
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN to the pedal with a clip. The pedal, bushings, pivot
BRAKE PARTS WITH COMPRESSED AIR OR BY pin and support bracket are all serviceable compo-
DRY BRUSHING. USE A VACUUM CLEANER SPE- nents.
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS. OPERATION
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- The brake pedal is attached to the booster push
ABLE, CLEANING SHOULD BE DONE WITH A rod. When the pedal is depressed, the primary
WATER DAMPENED CLOTH. DO NOT SAND, OR booster push rod is depressed which move the booster
GRIND BRAKE LINING UNLESS EQUIPMENT USED secondary rod. The booster secondary rod depress the
IS DESIGNED TO CONTAIN THE DUST RESIDUE. master cylinder piston.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS STOP LAMP SWITCH
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE DESCRIPTION
OCCUPATIONAL SAFETY AND HEALTH ADMINIS- The plunger type stop lamp switch is mounted on a
TRATION AND THE ENVIRONMENTAL PROTECTION bracket attached to the brake pedal support.
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY CAUTION: The switch can only be adjusted during
CONTAIN ASBESTOS FIBERS. initial installation. If the switch is not adjusted prop-
erly a new switch must be installed.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing OPERATION
mineral oil to clean the system components. These The brake lamp switch is used to for the brake
fluids damage rubber cups and seals. Use only lamp, speed control and brake sensor circuits. The
fresh brake fluid or Mopar brake cleaner to clean or brake lamp circuit is open until the plunger is
flush brake system components. These are the only
AN BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)
depressed. The speed control and brake sensor cir- malfunction. The reservoir compartments will retain
cuits is closed until the plunger is depressed. enough fluid to operate the functioning hydraulic cir-
cuit.
RED BRAKE WARNING LAMP Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
DESCRIPTION the cylinder fluid ports can be damaged if care is not
A red warning lamp is used for the service brake exercised. Start all brake line fittings by hand to
portion of the hydraulic system. The lamp is located avoid cross threading.
in the instrument cluster. The cylinder reservoir can be replaced when neces-
sary. However, the aluminum body section of the
OPERATION master cylinder is not a repairable component.
The red warning light alerts the driver if a pres-
sure differential exists between the front and rear NOTE: If diagnosis indicates that an internal mal-
hydraulic systems or the parking brakes are applied. function has occurred, the aluminum body section
The lamp is turned on momentarily when the igni- must be replaced as an assembly.
tion switch is turn to the on position. This is a self
test to verify the lamp is operational.
OPERATION
The master cylinder bore contains a primary and
POWER BRAKE BOOSTER
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
DESCRIPTION
piston supplies hydraulic pressure to the rear brakes.
All models use a tandem diaphragm, power brake
booster.
COMBINATION VALVE
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an DESCRIPTION
assembly if diagnosis indicates a malfunction has The combination valve contains a pressure differ-
occurred. ential valve and switch and a rear brake proportion-
ing valve. The valve is not repairable and must be
replaced as an assembly if diagnosis indicates this is
OPERATION necessary.
The booster unit consists of a single housing
divided into two by a tandem diaphragm. The outer OPERATION
edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the PRESSURE DIFFERENTIAL VALVE
brake pedal and master cylinder, is attached to the The pressure differential switch is connected to the
center of the diaphragm. A check valve is used in the brake warning light. The switch is actuated by move-
booster outlet connected to the engine intake mani- ment of the switch valve. The switch monitors fluid
fold. Power assist is generated by utilizing a combi- pressure in the separate front/rear brake hydraulic
nation of vacuum and atmospheric pressure to boost circuits.
brake assist. A decrease or loss of fluid pressure in either
hydraulic circuit will cause the switch valve to shut-
MASTER CYLINDER tle to the low pressure side. Movement of the valve
pushes the switch plunger upward. This action closes
DESCRIPTION the switch internal contacts completing the electrical
A two-piece master cylinder is used on all models. circuit to the red warning light. The switch valve will
The cylinder body containing the primary and sec- remain in an actuated position until repairs to the
ondary pistons is made of aluminum. The removable brake system are made.
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the PROPORTIONING VALVE
hydraulic brake circuits. The reservoir is the only The proportioning valve is used to balance front-
serviceable component. rear brake action at high decelerations. The valve
The fluid compartments of the nylon reservoir are allows normal fluid flow during moderate braking.
interconnected to permit fluid level equalization. The valve only controls fluid flow during high decel-
However, the equalization feature does not affect cir- erations brake stops.
cuit separation in the event of a front or rear brake
5-4 BRAKES AN
DESCRIPTION AND OPERATION (Continued)
FRONT DISC BRAKES Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
DESCRIPTION piston. Upon release of the pedal, the caliper and pis-
The calipers are a single piston type. The calipers ton return to a rest position. The brake shoes do not
are free to slide laterally, this allows continuous com- retract an appreciable distance from the rotor. In
pensation for lining wear. fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
OPERATION between the rotor and lining and in wiping the rotor
When the brakes are applied fluid pressure is surface clear each revolution.
exerted against the caliper piston. The fluid pressure The caliper piston seal controls the amount of pis-
is exerted equally and in all directions. This means ton extension needed to compensate for normal lining
pressure exerted against the caliper piston and wear.
within the caliper bore will be equal (Fig. 1). During brake application, the seal is deflected out-
ward by fluid pressure and piston movement (Fig. 2).
When the brakes (and fluid pressure) are released,
the seal relaxes and retracts the piston.
The amount of piston retraction is determined by
the amount of seal deflection. Generally the amount
is just enough to maintain contact between the pis-
ton and inboard brake shoe.
Fig. 2 Lining Wear Compensation By Piston Seal
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