Chrysler 1998 Voyager Service Manual page 106

5 - 24 BRAKES
SERVICE PROCEDURES (Continued)
Rotor Thick-
Braking Rotor
Front Rotor 23.87-24.13 mm
.939 -.949 in.
Rear Rotor 12.75-12.25 mm
.502 -.482 in.
* TIR Total Indicator Reading (Measured On Vehicle)
BRAKE DRUM MACHINING
Measure the runout and diameter of the rear brake
using only accurate measuring equipment. There
should be no variation in the drum diameter greater
than 0.090 mm (0.004 inch). Drum runout should not
exceed 0.15 mm (0.006 inch) out of round. If the
drum runout or diameter variation exceed these val-
ues the drum should be refaced. For best results in
eliminating the irregularities that cause brake rough-
ness and surge, the amount of material removed dur-
ing a single cut should be limited to 0.13 mm (0.005
inch). When the entire braking surface has been
cleaned. A final cut of 0.0254 mm (0.001 inch) will
assure a good drum surface providing the equipment
used is capable of the precision required for resurfac-
ing brake drums. Deeper cuts are permissible for the
sole purpose of removing deep score marks. Do not
reface more than 1.52 mm (0.060 inch) over the
standard drum diameter.
All drums will show markings of maximum allow-
able diameter (Fig. 36). For example, a drum will
have a marking of MAX. DIA. 251.55 mm (9.90 inch).
This marking includes 0.76 mm (0.030 inch) for
allowable drum wear beyond the recommended 1.52
mm (0.060 inch) of drum refacing
Fig. 36 Rear Brake Drum Maximum Diameter
Identification
ROTOR REFINISHING LIMITS
Minimum Rotor
ness Thickness
22.4 mm
.881 in.
11.25 mm
.443 in.
Rotor Thick- Rotor Run
ness Variation
.013 mm
.0005 in.
.013 mm
.0005 in.
BRAKE TUBE REPAIR PROCEDURE
CAUTION: When repairing brake chassis lines or
flex hoses, the correct fasteners must be used to
attach the routing clips or hoses to the front sus-
pension cradle. The fasteners used to attach com-
ponents to the front suspension cradle have an
anti-corrosion coating due to the suspension cradle
being made of aluminum. Only Mopar replacement
fasteners with the required anti-corrosion coating
are to be used if a replacement fastener is required
when installing a brake chassis line or flex hose.
Only double wall 4.75mm (3/16 in.) steel tubing
with Al-rich/ZW-AC alloy coating and the correct tube
nuts are to be used for replacement of a hydraulic
brake tube.
NOTE: On vehicles equipped with traction control,
the primary and secondary hydraulic tubes between
the master cylinder and the hydraulic control unit
are 6 mm (15/64 in.). These tubes are also coated
with the Al-rich/ZW-AC alloy and must be replaced
with tubes having the same anti-corrosion coating.
Be sure the correct tube nuts are used for the
replacement of these hydraulic brake tubes.
Care should be taken when repairing brake tubing,
to be sure the proper bending and flaring tools and
procedures are used, to avoid kinking. Do not route
the tubes against sharp edges, moving components or
into hot areas. All tubes should be properly attached
with recommended retaining clips.
If the primary or secondary brake line from the
master cylinder to the ABS Hydraulic Control Unit,
or the flexible brake lines between the hydraulic con-
trol unit and the proportioning valve require replace-
ment only the original factory brake lines containing
a flexible section can be used. This is required due to
the movement of the front suspension cradle while
the vehicle is in motion.
Using Tubing Cutter, Special Tool C-3478-A or
equivalent, cut off damaged seat or tubing (Fig. 37).
Ream out any burrs or rough edges showing on
inside of tubing (Fig. 38). This will make the ends of
tubing square (Fig. 38) and ensure better seating of
Rotor Micro
Out* Finish
.08 mm 15-80 RMS
.003 in.
.08 mm 15-80 RMS
.003 in.
NS