Dodge Sprinter 2006 Manual page 804

5 - 20 BRAKES - BASE
edge of t h e dia ph r a gm is secu r ed t o t h e h ou sin g. Th e
boost er pu sh r od, wh ich con n ect s t h e boost er t o t h e
br a ke peda l a n d m a st er cylin der, is a t t a ch ed t o t h e
cen t er of t h e dia ph r a gm . A ch eck va lve is u sed in t h e
boost er ou t let con n ect ed t o t h e en gin e in t a ke m a n i-
fold. P ower a ssist is gen er a t ed by u t ilizin g a com bi-
n a t ion of va cu u m a n d a t m osph er ic pr essu r e t o boost
br a ke a ssist .
REMOVAL
(1) Usin g a su ct ion gu n r em ove a s m u ch br a ke
flu id fr om t h e r eser voir a s possible.
(2) Discon n ect t h e br a ke level swit ch elect r ica l
con n ect or.
(3) Rem ove t h e br a ke lin es fr om t h e m a st er cylin -
der S e a l o ff th e e n d s a n d bo re h o le s w ith p lu g s .
(4) Rem ove t h e m a st er cylin der fr om t h e boost er.
(5) Rem ove t h e boost er va cu u m h ose a n d ch eck
va lve (F ig. 23).
(6) Rem ove t h e peda l pu sh r od clip (F ig. 23).
(7) Rem ove t h e boost er m ou n t in g n u t s (F ig. 23).
(8) Rem ove t h e boost er fr om t h e veh icle.
Fig. 23 POWER BRAKE BOOSTER
1 - VACUUM LINE & CHECK VALVE
2 - BRAKE BOOSTER
3 - GASKET
4 - MOUNTING NUTS (4)
5 - PUSH ROD PIN
6 - SECURING CLIP
INSTALLA TION
(1) In st a ll t h e br a ke boost er t o t h e veh icle.
(2) In st a ll t h e boost er m ou n t in g n u t s (F ig. 23).
Tigh t en t o 25 N·m (221 in .lbs.).
(3) In st a ll t h e pu sh r od pin & clip (F ig. 23).
(4) In st a ll t h e br a ke boost er va cu u m lin e a n d
ch eck va lve (F ig. 23).
(5) In st a ll t h e m a st er
boost er. Tigh t en t o 28 N·m (248 in .lbs.).
(6) In st a ll t h e br a ke lin es t o t h e m a st er cylin der.
Tigh t en t o 14 N·m (124 in .lbs.).
(7) In st a ll t h e br a ke level swit ch elect r ica l con n ec-
t or.
cylin der t o t h e br a ke
(8) Bleed t h e ba se br a ke syst em (Refer t o 5 -
BRAKE S - STANDARD P ROCE DURE ).
ROT ORS
REM OVAL
REMOVAL - FRONT (SRW)
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e fr on t wh eels.
(3) Rem ove t h e fr on t br a ke pa ds (F ig. 24).
(4) Rem ove t h e ca liper a da pt er (F ig. 24).
(5) In st a ll t wo lu g st u ds t o secu r e t h e disc br a ke
r ot or wh en t h e lockin g bolt is r em oved.
(6) Rem ove t h e lockin g bolt for t h e disc br a ke r ot or
(F ig. 24).
(7) Rem ove t h e t wo lu g n u t s.
(8) Rem ove t h e disc br a ke r ot or (F ig. 24).
Fig. 24 FRONT DISC BRAKE ROTOR
1 - CALIPER ADAPTER BOLT
2 - CALIPER ADAPTER
3 - GUIDE BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
REMOVAL - REAR (SRW)
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e r ea r wh eels.
(3) Rem ove t h e r ea r disc br a ke pa ds (F ig. 25).
(4) Rem ove t h e disc br a ke ca liper a da pt er (F ig.
25).
(5) Apply t h e pa r kin g br a ke.
(6) In st a ll t wo lu g st u ds t o secu r e t h e disc br a ke
r ot or wh en t h e lockin g bolt is r em oved.
(7) Rem ove t h e lockin g bolt for t h e disc br a ke r ot or
(F ig. 25).
(8) Rem ove t h e t wo lu g n u t s.
(9) Relea se t h e pa r kin g br a ke.
VA