Standard Procedure - Bleeding; Removal; Installation - Dodge dakota 2002 Service Manual

DR
HYDRO-BOOST BRAKE BOOSTER (Continued)
CONDITION
Brakes Self Apply
Booster Chatter, Pedal
Vibration
Grabbing Brakes

STANDARD PROCEDURE - BLEEDING

The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.

REMOVAL

NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 49).
POSSIBLE CAUSES
1. Dump valve faulty.
2. Contamination in hydraulic
system.
3. Restriction in booster return hose.
1. Slipping pump belt.
2. Low pump fluid level.
1. Low pump flow.
2. Faulty spool valve action.
1. Replace booster.
2. Flush hydraulic system and replace
booster.
3. Replace hose.
1. Replace power steering belt.
2. Fill pump and check for leaks.
1. Test and repair/replace pump.
2. Replace booster.
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal.
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster.
Fig. 49 HYDRO-BOOST UNIT
1 - INLET HOSE
2 - HYDRO-BOOST UNIT
3 - MASTER CYLINDER UNIT
4 - RETURN HOSE
5 - OUTLET HOSE

INSTALLATION

(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N·m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N·m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N·m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N·m (17 ft. lbs.).
BRAKES - BASE
CORRECTION
5 - 27