Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Durango 1998-2000 Approved Dodge Durango 2000 00dn_5
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download 00dn_5 documenatation <<
Text preview - extract from the document
DN 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
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 14
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 15
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 16
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 3 DISC BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . . 17
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3 REAR BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . 19
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 3 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 21
DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . . 21
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5 REAR PARK BRAKE CABLES . . . . . . . . . . . . . . . 22
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . . 5 PARK BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 5 MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 23
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 8 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 24
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 27
MASTER CYLINDER/POWER BOOSTER . . . . . . . . 8 CLEANING AND INSPECTION
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 9 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 27
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 10 ADJUSTMENTS
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 10 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE PROCEDURES PARK BRAKE CABLE TENSIONER . . . . . . . . . . . 30
BRAKE FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . 11 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 12 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 12 SPECIAL TOOLS
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . . 12 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13
5-2 BRAKES DN
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 pin 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
DN 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 The combination valve contains a pressure differ-
component. The booster must be replaced as an ential valve and switch and a proportioning valve.
assembly if diagnosis indicates a malfunction has The combination valve/proportioning valve are not
occurred. repairable and must be replaced as an assembly.
PRESSURE DIFFERENTIAL SWITCH
OPERATION The pressure differential switch is connected to the
The booster unit consists of a single housing brake warning lamp. The switch is triggered by
divided into two by a tandem diaphragm. The outer movement of the switch valve. The purpose of the
edge of the diaphragm is secured to the housing. The switch is to monitor fluid pressure in the separate
booster push rod, which connects the booster to the front/rear brake hydraulic circuits.
brake pedal and master cylinder, is attached to the A decrease or loss of fluid pressure in either
center of the diaphragm. A check valve is used in the hydraulic circuit will cause the switch valve to shut-
booster outlet connected to the engine intake mani- tle forward or rearward in response to the pressure
fold. Power assist is generated by utilizing a combi- differential. Movement of the switch valve will push
nation of vacuum and atmospheric pressure to boost the switch plunger upward. This closes the switch
brake assist. internal contacts completing the electrical circuit to
the warning lamp. The switch valve may remain in
MASTER CYLINDER an actuated position until repair restores system
pressures to normal levels.
DESCRIPTION
A two-piece master cylinder is used on all models. PROPORTIONING VALVE
The cylinder body containing the primary and sec- The proportioning valve is used to balance front-
ondary pistons is made of aluminum. The removable rear brake action at high decelerations. The valve
fluid reservoir is made of nylon reinforced with glass allows normal fluid pressure during moderate brak-
fiber. The reservoir stores reserve brake fluid for the ing. The valve only controls fluid pressure during
hydraulic brake circuits. The reservoir is the only high decelerations brake stops, when a percentage of
serviceable component. rear weight is transferred to the front wheels.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
cuit separation in the event of a front or rear brake
5-4 BRAKES DN
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
1 ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo