Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Durango 1998-2000 Approved Dodge Durango 1998-99 98DN_5
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DN BRAKES 5-1
BRAKES
CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 1 REAR WHEEL ANTILOCK BRAKES . . . . . . . . . . . 28
FOUR WHEEL ANTILOCK BRAKES . . . . . . . . . . . 36
BASE BRAKE SYSTEM
INDEX
page page
GENERAL INFORMATION BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . 18
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 13
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . 2 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 15
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . 4 DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . 14
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . 18
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 3 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 13
DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PARK BRAKE PEDAL ASSEMBLY . . . . . . . . . . . 19
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 3 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 13
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 3 REAR BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 16
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 4 REAR PARK BRAKE CABLES . . . . . . . . . . . . . . 18
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 2 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 12
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 2 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 17
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 21
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 4 MASTER CYLINDER RESERVOIR . . . . . . . . . . . 20
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 23
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 9 CLEANING AND INSPECTION
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 8 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 23
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 24
MASTER CYLINDER/POWER BOOSTER . . . . . . . 7 ADJUSTMENTS
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 7 PARK BRAKE CABLE TENSIONER . . . . . . . . . . 26
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 7 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 24
SERVICE PROCEDURES STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 24
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 11 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 9 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 27
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . . 11 SPECIAL TOOLS
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 9 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL AND INSTALLATION
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2 BRAKES DN
GENERAL INFORMATION cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
BRAKE SYSTEM oration, or separation into distinct layers. Also
This vehicle is equipped with front disc brakes and check the reservoir cap seal for distortion. Drain
rear drum brakes. The front disc brakes consist of and flush the system with new brake fluid if con-
single piston calipers and ventilated rotors. The rear tamination is suspected.
brakes are dual brake shoe, internal expanding units
with cast brake drums. The parking brake mecha-
CAUTION: Use Mopar brake fluid, or an equivalent
nism is cable operated and connected to the rear
quality fluid meeting SAE/DOT standards J1703 and
brake trailing shoes. Power brake assist is standard
DOT 3. Brake fluid must be clean and free of con-
equipment. A vacuum operated power brake booster
taminants. Use fresh fluid from sealed containers
is used for all applications.
only to ensure proper antilock component opera-
Two antilock brake systems are used on this vehi-
tion.
cle. A rear wheel antilock (RWAL) brake system is
standard. An all-wheel antilock brake system (ABS)
is available as an option. The RWAL and ABS sys- CAUTION: Use Mopar multi-mileage or high temper-
tems are designed to retard wheel lockup while brak- ature grease to lubricate caliper slide surfaces,
ing. Retarding wheel lockup is accomplished by drum brake pivot pins, and shoe contact points on
modulating fluid pressure to the wheel brake units. the backing plates. Use multi-mileage grease or GE
Both systems are monitored by a microprocessor 661 or Dow 111 silicone grease on caliper slide pins
which controls the operation of the systems. to ensure proper operation.
SERVICE WARNINGS & CAUTIONS
WARNING: DUST AND DIRT ACCUMULATING ON DESCRIPTION AND OPERATION
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM AFTERMARKET BRAKE PEDAL
LININGS. BREATHING EXCESSIVE CONCENTRA- A suspended-type brake pedal is used. The pedal is
TIONS OF ASBESTOS FIBERS CAN CAUSE SERI- attached to the pedal support bracket with a pivot
OUS BODILY HARM. EXERCISE CARE WHEN pin and bushings. The booster push rod is attached
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. STOP LAMP SWITCH
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- The stop lamp switch is mounted on a bracket on
ABLE, CLEANING SHOULD BE DONE WITH A the brake pedal support. The switch is self adjusting.
WATER DAMPENED CLOTH. DO NOT SAND, OR An initial adjustment is only necessary when the
GRIND BRAKE LINING UNLESS EQUIPMENT USED switch has been replaced, or removed for service
IS DESIGNED TO CONTAIN THE DUST RESIDUE. access to other components.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS RED BRAKE WARNING LAMP
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- A red warning lamp is used for the service brake
ERS. FOLLOW PRACTICES PRESCRIBED BY THE portion of the hydraulic system. The lamp is located
OCCUPATIONAL SAFETY AND HEALTH ADMINIS- in the instrument cluster. The red warning light
TRATION AND THE ENVIRONMENTAL PROTECTION alerts the driver if a pressure differential exists
AGENCY FOR THE HANDLING, PROCESSING, AND between the front and rear hydraulic systems or the
DISPOSITION OF DUST OR DEBRIS THAT MAY parking brakes are applied.
CONTAIN ASBESTOS FIBERS. The lamp is turned on momentarily when the igni-
tion switch is turn to the on position. This is a self
test to verify the lamp is operational.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing POWER BRAKE BOOSTER
mineral oil to clean the system components. These All models are equipped with power assist brakes.
fluids damage rubber cups and seals. Use only A tandem diaphragm, power brake booster is used for
fresh brake fluid or Mopar brake cleaner to clean or all applications.
flush brake system components. These are the only
DN BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)
The booster unit consists of a single housing A decrease or loss of fluid pressure in either
divided into chambers by a tandem diaphragm. The hydraulic circuit will cause the switch valve to shut-
outer edge of the diaphragm is secured to the hous- tle forward or rearward in response to the pressure
ing. The booster push rod, which connects the booster differential. Movement of the switch valve will push
to the brake pedal and master cylinder, is attached to the switch plunger upward. This closes the switch
the center of the diaphragm. A check valve is used in internal contacts completing the electrical circuit to
the booster outlet connected to the engine intake the warning lamp. The switch valve may remain in
manifold. Power assist is generated by utilizing a an actuated position until repair restores system
combination of vacuum and atmospheric pressure to pressures to normal levels.
boost brake assist.
PROPORTIONING VALVE
NOTE: The power brake booster is not a repairable The proportioning valve is used to balance front-
component. The booster must be replaced as an rear brake action at high decelerations. The valve
assembly if diagnosis indicates a malfunction has allows normal fluid pressure during moderate brak-
occurred. ing. The valve only controls fluid pressure during
high decelerations brake stops, when a percentage of
rear weight is transferred to the front wheels.
MASTER CYLINDER
A two-piece master cylinder is used on all models. FRONT DISC BRAKES
The cylinder body containing the primary and sec- The calipers are a single piston type. The calipers
ondary pistons is made of aluminum. The removable are free to slide laterally, this allows continuous com-
fluid reservoir is made of nylon reinforced with glass pensation for lining wear.
fiber. The reservoir is the only serviceable compo- When the brakes are applied fluid pressure is
nent. exerted against the caliper piston. The fluid pressure
The fluid compartments of the nylon reservoir are is exerted equally and in all directions. This means
interconnected to permit fluid level equalization. pressure exerted against the caliper piston and
However, the equalization feature does not affect cir- within the caliper bore will be equal (Fig. 1).
cuit separation in the event of a front or rear brake
malfunction. The reservoir compartments will retain
enough fluid to operate the functioning hydraulic cir-
cuit.
Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
the cylinder fluid ports can be damaged if care is not
exercised. Start all brake line fittings by hand to
avoid cross threading.
The cylinder reservoir can be replaced when neces-
sary. However, the aluminum body section of the
master cylinder is not a repairable component.
NOTE: If diagnosis indicates that an internal mal-
function has occurred, the aluminum body section
must be replaced as an assembly.
COMBINATION VALVE
The combination valve contains a pressure differ-
ential valve and switch and a proportioning valve.
The combination valve/proportioning valve are not
repairable and must be replaced as an assembly.
PRESSURE DIFFERENTIAL SWITCH Fig. 1 Brake Caliper Operation
The pressure differential switch is connected to the Fluid pressure applied to the piston is transmitted
brake warning lamp. The switch is triggered by directly to the inboard brake shoe. This forces the
movement of the switch valve. The purpose of the shoe lining against the inner surface of the disc
switch is to monitor fluid pressure in the separate brake rotor. At the same time, fluid pressure within
front/rear brake hydraulic circuits. the piston bore forces the caliper to slide inward on
5-4 BRAKES DN
DESCRIPTION AND OPERATION (Continued)
the mounting bolts. This action brings the outboard
brake shoe lining into contact with the outer surface
of the disc brake rotor.
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will stop the rotors from turning and bring the vehi-
cle to a stop.
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake shoes do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seal controls the amount of pis-
ton extension needed to compensate for normal lining
wear.
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,
Fig. 3 Brake Assembly
the seal relaxes and retracts the piston.
The amount of piston retraction is determined by The parking brake pedal assembly is mounted on
the amount of seal deflection. Generally the amount the driver side cowl panel. The front cable is directly
is just enough to maintain contact between the pis- attached to the assembly. The pedal assembly con-
ton and inboard brake shoe. tains a spring loaded mechanism to hold the pedal in
the applied position. A rod is used to release the
ratchet mechanism and return the pedal to released
position.
BRAKE HOSES AND LINES
Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Double walled
steel tubing is used to connect the master cylinder to
the major hydraulic braking components and then to
the flexible rubber hoses.
Fig. 2 Lining Wear Compensation By Piston Seal DIAGNOSIS AND TESTING
DRUM BRAKES BASE BRAKE SYSTEM
Drum brakes on all models are dual shoe, internal Base brake components consist of the brake shoes,
expanding units with an automatic self adjusting calipers, wheel cylinders, brake drums, rotors, brake
mechanism (Fig. 3). Eleven inch brakes are used on lines, master cylinder, booster, and parking brake
all models. components.
Brake diagnosis involves determining if the prob-
PARKING BRAKES lem is related to a mechanical, hydraulic, or vacuum
The parking brakes are operated by a system of operated component.
cables and levers attached to the rear brake second- The first diagnosis step is the preliminary check.
ary shoes.
The rear drum brake shoes serve as the parking PRELIMINARY BRAKE CHECK
brakes. The shoes make contact with the brake drum (1) Check condition of tires and wheels. Damaged
surface by a cable and lever mechanism attached to wheels and worn, damaged, or underinflated tires
the secondary brake shoe. can cause pull, shudder, vibration, and a condition
similar to grab.
DN BRAKES 5-5
DIAGNOSIS AND TESTING (Continued)
(2) If complaint was based on noise when braking, An internal leak in the ABS or RWAL system may
check suspension components. Jounce front and rear also be the problem with no physically evident.
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering LOW PEDAL
components. If a low pedal is experienced, pump the pedal sev-
(3) Inspect brake fluid level and condition. Note eral times. If the pedal comes back up worn linings,
that the brake reservoir fluid level will decrease in rotors, drums, or rear brakes out of adjustment are
proportion to normal lining wear. Also note that the most likely causes. The proper course of action is
brake fluid tends to darken over time. This is to inspect and replace all worn component and make
normal and should not be mistaken for contam- the proper adjustments.
ination.
(a) If fluid level is abnormally low, look for evi- SPONGY PEDAL
dence of leaks at calipers, wheel cylinders, brake A spongy pedal is most often caused by air in the
lines, and master cylinder. system. However, thin brake drums or substandard
(b) If fluid appears contaminated, drain out a brake lines and hoses can also cause a spongy pedal.
sample to examine. System will have to be flushed The proper course of action is to bleed the system,
if fluid is separated into layers, or contains a sub- and replace thin drums and substandard quality
stance other than brake fluid. The system seals brake hoses if suspected.
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system. HARD PEDAL OR HIGH PEDAL EFFORT
(4) Check parking brake operation. Verify free A hard pedal or high pedal effort may be due to
movement and full release of cables and pedal. Also lining that is water soaked, contaminated, glazed, or
note if vehicle was being operated with parking badly worn. The power booster or check valve could
brake partially applied. also be faulty.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal PEDAL PULSATION
lacks free play, check pedal and power booster for Pedal pulsation is caused by components that are
being loose or for bind condition. Do not road test loose, or beyond tolerance limits.
until condition is corrected. The primary cause of pulsation are disc brake
(6) Check booster vacuum check valve and hose. rotors with excessive lateral runout or thickness vari-
(7) If components checked appear OK, road test ation, or out of round brake drums. Other causes are
the vehicle. loose wheel bearings or calipers and worn, damaged
tires.
ROAD TESTING
(1) If complaint involved low brake pedal, pump NOTE: Some pedal pulsation may be felt during
pedal and note if it comes back up to normal height. ABS activation.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
BRAKE DRAG
firm under constant foot pressure.
(3) During road test, make normal and firm brake Brake drag occurs when the lining is in constant
stops in 25-40 mph range. Note faulty brake opera- contact with the rotor or drum. Drag can occur at one
tion such as low pedal, hard pedal, fade, pedal pulsa- wheel, all wheels, fronts only, or rears only.
tion, pull, grab, drag, noise, etc. Drag is a product of incomplete brake shoe release.
(4) Attempt to stop the vehicle with the parking Drag can be minor or severe enough to overheat the
brake only and note grab, drag, noise, etc. linings, rotors and drums.
Minor drag will usually cause slight surface char-
PEDAL FALLS AWAY ring of the lining. It can also generate hard spots in
A brake pedal that falls away under steady foot rotors and drums from the overheat-cool down pro-
pressure is generally the result of a system leak. The cess. In most cases, the rotors, drums, wheels and
leak point could be at a brake line, fitting, hose, or tires are quite warm to the touch after the vehicle is
caliper/wheel cylinder. If leakage is severe, fluid will stopped.
be evident at or around the leaking component. Severe drag can char the brake lining all the way
Internal leakage (seal by-pass) in the master cylin- through. It can also distort and score rotors and
der caused by worn or damaged piston cups, may drums to the point of replacement. The wheels, tires
also be the problem cause. However, internal leakage and brake components will be extremely hot. In
in the master cylinder, ABS or RWAL system may severe cases, the lining may generate smoke as it
not be physically evident. chars from overheating.
5-6 BRAKES DN
DIAGNOSIS AND TESTING (Continued)
Common causes of brake drag are: particularly true when only one rear wheel is
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