Chrysler Ramcharger D150-400 1980 Service Manual
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Chrysler Ramcharger D150-400 1980 Service Manual

Chrysler Ramcharger D150-400 1980 Service Manual

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  • Page 2 CHRYSLER CORPORATION 23 Bot,y Chrysler Corporation reserves the right to make changes in design or to Heaters and Air-Condition7ng~^ make additions to or improvements in its products without imposing any cb ligations upon itself to install them on its products previously manufacture-! Emissions Control Systems Litho in U.

  • Page 3: Table Of Contents

    BLEEDING BRAKE SYSTEM...... HYDRAULIC BRAKE SYSTEM....BRAKE ADJUSTMENT DUO-SERVO ..MASTER CYLINDER INTERNAL LEAK BRAKE HOSE AND TUBING....... CHECK ............ DISC BRAKE—CHRYSLER (D150, D200, MASTER CYLINDER D300, D400, AD 100, PD100) ....ALUMINUM ........DISC BRAKE—BENDIX (W300, W400 & CAST IRON..........
  • Page 4 BRAKES BASIC DIAGNOSIS GUIDE Chart 1 Chart 2 Chart 3 Chart 4 Chart 5 Misc. Cond. Actuation Power Noise Wheel Brakes Symptom Brake Warning Light "ON" Brake Chatter (Rough) Surge During Braking Noise During Braking Pull to Right or Left Premature Rear Lockup Rear Brakes Drag Brakes Drag—ALL...
  • Page 5 ♦ BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS...
  • Page 6 BRAKES BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS PH 63-s...
  • Page 7 -BRAKES BRAKE CHART 4 BRAKE NOISE DIAGNOSIS “INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED "WAYS" OF CALIPER AND ADAPTER. ♦♦♦MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. PU57 BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED O'? -ED'.'C?D BY DOTATION DRUM (REAR) TWO PH 632E STUDS ON AXLE FLANGE.

  • Page 8: Hydraulic Brake System

    BRAKES—HYDRAULIC SERVICE PROCEDURES HYDRAULIC BRAKE SYSTEM into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. Servicing the hydraulic system is chiefly a matter of Be safe and discard old brake fluid that has been bled adjustments, replacement of worn or damaged parts from the system.
  • Page 9 ♦------------------------------------------------------------------------------------------------------------------——------------------- HYDRAULIC— BRAKES falling into the master cylinder reservoir when the (2) Pedal Bleed: This method of bleeding is not af­ cover is removed. fected by the hold-off valve, as fluid pressures are in (1) Check brake master cylinder to be sure boot is excess of 165 psi (1137.6 kPa).

  • Page 10: Brake Adjustment Duo-Servo

    BRAKES—HYDRAULIC In a trapped air condition, the brake warning light Move handle of tool downward until a slight drag i will go off when brake pedal is released. felt when road wheel is rotated. If warning light does not go off after you release (5) For application Type adjuster (Fig.

  • Page 11: Brake Hose And Tubing

    HYDRAULIC—BRAKES properly. If by the described procedure one or more Always use factory recommended hose to insure automatic adjusters do not function properly, the re- quality, correct length and superior fatigue life. Care -oeetive drum must be removed for adjuster serv- should be taken to make sure that the tube and hose mating surfaces are clean and free from nicks and burrs.

  • Page 12: General Information

    (11) Clean seat and tube of any lubricant before (7) Place proper sized plug of gauge “A” down in connecting to hydraulic system. DISC BRAKE-CHRYSLER (D150, D200, D300, D400, AD 100/ PD 100) INDEX Page Page Assembling Caliper..........
  • Page 13 DISC (SLIDING CALIPER)—BRAKES 5-11 a hydraulic seal between the piston and the cylinder CALIPER wall (Fig. 3). The adaptor is mounted to the steering knuckle by two special nylock bolts (Figs. 1 and 3). A moulded rubber dust boot installed in a groove in the cylinder bore and piston keeps contamination RETENTION FLANGE...
  • Page 14 5-12 BRAKES—DISC (SLIDING CALIPER) PISTON -BRAKE FLUID WHEEL STUD- SPINDLE BEARING BRAKING DISC- AND HUB NU4C Fig. 3—Disc Brake Assembly Sectional)

  • Page 15: Routine Maintenance

    DISC (SLIDING CALIPER)—BRAKES 5-13 ♦. Fig. 5—Piston Seal Function For Automatic Adjustment inspected at this time and replaced if necessary). The caliper assembly must be removed in order to inspect the inner wheel bearings. (Refer to “Brake Shoe Re­ moval” paragraph). Do not get oil or grease on the braking disc or lin­...

  • Page 16: Brake Shoe Installation

    ♦ 5-14 BRAKES—DISC (SLIDING CALIPER) Fig. 6—Removing or Installing Caliper mating surfaces of the abutments on the caliper and adaptor. If corroded or rusty, clean surfaces with wire Fig. 8—Removing or Installing Shoe brush. Inspect braking surfaces of disc. shoe after above modification, if necessary, by snap­ BRAKE SHOE INSTALLATION ping shoe into place with fingers or with light “C”...

  • Page 17: Disassembling Caliper

    ♦ DISC (SLIDING CALIPER)—BRAKES 5-15 (7) Check and refill master cylinder reservoirs (if necessary) with DOT 3 brake fluid as required. It should not be necessary to bleed the system after -^oe and lining removal and installation. However, if irm pedal cannot be obtained bleed the brake sys­ tem as described in “Bleeding the Brake System”...

  • Page 18: Assembling Caliper

    5-16 BRAKES—DISC (SLIDING CALIPER) PF506 Fig. 13—Removal of Dust Boot PF507 protector jaws. Caution: Excessive vise pressure will cause bore distortion and binding of piston. Fig. 14—Removing Piston Seal (6) Remove dust boot (Fig. 13). ASSEMBLING CALIPER (7) Using a small, pointed, wooden or plastic stick, work piston seal out of its groove in piston bore (Fig.

  • Page 19: Installing Caliper

    DISC (SLIDING CALIPER)—BRAKES 5-17 PF510 Fig. 17—Installing Piston Dust Boot Fig. 16-Installing Piston Seal (3) Slowly slide caliper assembly into position in adaptor and .er disc. Align caliper on machined (4) Plug high pressure inlet to caliper and bleeder ways of adaptor. Be careful not tc ,11 the dust boot screw hole, then coat piston with clean brake fluid.
  • Page 20 5-18 BRAKES—DISU (ROTOR) under maximum pedal pressures. (Recheck master the master cylinder during the bleeding operation cylinder reservoir level). Never use brake fluid that has been drained from fhi (8) Install wheel and tire assembly. Tighten stud hydraulic system, when bleeding the brakes. nuts as described in “Wheels, Bearings and Tires"...

  • Page 21: Service Procedures

    ♦ DISC (ROTOR)—BRAKES 5-19 SERVICE PROCEDURES CHECKING BRAKING DISC FOR RUNOUT D150, AD100, PD100 D200, D300, D400 *ND THICKNESS Runout .004 Inch .005 Inch _________________(-101 mm)_________ (.127 mm) (1) Mount dial indicator C-3339 on steering arm Thickness .0005 Inch .001 Inch with plunger contacting disc approximately one (1) Variation________ (.0127 mm)_________ (.025 mm) inch (25.4mm) from the edge of the disc (Fig.

  • Page 22: Refinishing (Refacing) Braking Disc

    5-20 DISC (ROTOR)—BRAKES (7) Install caliper assembly, as described in “I remove as little as possible from each side of disc. Remove equal amounts from each side of disc. Do not stalling Caliper” paragraph. reduce thickness below minimum thickness shown in REFINISHING (REFACING) BRAKING DISC refinishing section of this Group.
  • Page 23 ♦ -SERVICE—BRAKES 5-21 DISC BRAKE-CHRYSLER (W150, W200, AW100, PWIOO) INDEX Page Page Assembling Caliper..........Hold-Off Valves............Brake Roughness ............. Installing Caliper ............. Brake Shoe Installation .......... Removing Caliper from Vehicle....... Brake Shoe Removal..........Routine Maintenance ..........Cleaning and Inspection.......... Service Diagnosis.............
  • Page 24 5-22 BRAKES—SERVICE...
  • Page 25 -----------------------------------------------------------------------------—- ♦ —------------- ---------- SERVICE—BRAKES 5-23 transmitted to the inboard brake shoe and lining and shoe and lining assemblies, (inboard and outboard) on the inboard braking surface of the disc. As force in­ the front wheels. It is necessary that both front wheel creases against the disc from the inner lining, the sets be replaced whenever a respective shoe and lin­...
  • Page 26 5-24 BRAKES—SERVICE ----------- ——------------------------------------------------------------------------------------------------------------ ------------------------ ♦ must be removed before removal of the hub and disc overflow may occur when the piston is pushed back isembly. into the new lining position. Overflowing can be (9) As lining wears, reservoir level will go down. If avoided in this case by removal of a small amount of fluid has been added between relines, then reservoir fluid before overflow occurs.

  • Page 27: Removing Caliper From Vehicle

    -SERV 5-25 brakes outboard CALIPER MACHINED "W SHOE RETAINER ’ » •/ . . *4.:.. FLANGE. \ " ■ft CALIPER F'NGER OUTBOARD SHOE MACHINED RETAINER LEDGE REACTION FLANGE PF5I6 Fig. 9—Caliper Finger and Outboard Shoe Retainer Flange REMOVING CALIPER FROM VEHICLE It will be necessary to remove the caliper to install a new piston seal and boot.
  • Page 28 5-26 BRAKES—SERVICE Fig. 1J—Attaching Shoe to Caliper Fingers with "C" Clamp PF506 DISASSEMBLING CALIPER Fig. 12—Removal of Dust Boot After removing caliper assembly from adaptor show light scratches or corrosion, can usually b( (with brake hose attached) as described above, com­ cleared with crocus cloth, However, bores that have plete disassembly as follows.

  • Page 29: Service Brakes

    ♦ SERVICE-BRAKES 5-27 Fig. 14-Honing Piston Bore ing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth PF510 and then clean a second time in the same manner or until clean cloth shows no signs of discoloration. Fig.

  • Page 30: Braking Disc (D150, D200, D300, D400, Ad100, Pd100)

    5-28 BRAKES—SERVICE ♦ INSTALLING CALIPER ways of adaptor. Be careful not to pull the dust boot from its gr^cvo a> me piston and boot slide over the Examine lining for wear, damage or fluid contami­ inboard shoe. nation if its condition is found satisfactory it may be (4) Install anti-rattle springs and retaining clips reused.
  • Page 31 SERVICE—BRAKES 5-29 (4) Light scoring and/or wear is acceptable. If heavy scoring or warping is evident the disc should be replaced. If cracks are evident the disc must be olaced. Do not reface a disc brake rotor more than .030 inch (.762mm) less than the original disc minimum thickness.
  • Page 32 5-30 BRAKES—SERVICE ♦ DISC BRAKE-BENDIX (W300, W400 and W200 Extra) INDEX Page Page Brake Shoe, Caliper—Inspection ......General Information ..........Brake Shoe, Caliper—Installation ......Hold-Off Valves............Brake Shoe, Caliper—Removal....... Operation ..............Caliper Overhaul ............Routine Maintenance ..........Cleaning and Inspection.......... Specifications ............

  • Page 33: Routine Maintenance

    SERVICE—BRAKES 5-31 For valve application and service, see “Hydraulic tnder- This moves the piston outward and forces System Control Valves", this group. -jfinner shoe and lining assembly against the in- Srd surface of the rotor. , reaction of the inner lining pressing against ROUTINE MAINTENANCE the rotor moves the caliper housing slightly inboard, outer legs of the caliper housing force the outer...

  • Page 34: Specifications

    5-32 BRAKES—SERVICE ----------------------------------------------------------------------- ♦ roughness will not clear up and the disc must be re- servicing any of the front end components to avoid nlaced. bending or damaging disc splash shield on full right or left hand turns. DISC BRAKE SERVICE PRECAUTIONS (6) Before vehicle is moved after any brake service work, be sure and obtain a firm brake pedal by using (1) Grease or any other foreign material must be...
  • Page 35 SERVICE—BRAKES 5-33 leave reservoir 1/3 full. When the caliper pistons are If boot is damaged or fluid leaks are evident, it will pressed back into the cylinder bores, brake fluid may be necessary tc overhaul caiiper. overflow if fluid is not removed. Discard the fluid re­ (3) Use a wire brush to remove any rust or corro­...

  • Page 36: Caliper Overhaul

    5-34 BRAKES—SERVICE Fig. 9—Pressing Outboard Shoe onto Caliper Arms With "C" Clamp BRASS ROD PK724 stall the assembly between the adapter and lower Fig. 11 —Installing Caliper Key and Spring caliper machined surfaces. Tap the assembly into position with brass punch and light hammer (Fig. 11.) stands.
  • Page 37 ♦ SERVICE—BRAKES 5-35 harm. When using a hone, coat the stones with brake CALIPER fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. Use extreme care in cleaning the caliper after hon­ ing.
  • Page 38 s-Jb BRAKES—SERVICE ♦ must be applied uniformly to avoid cocking piston torque to 25 foot pounds (38.8 N-m). (Fig. 14). (3) Remove brake pedal prop, fill master cylinder reservoir (to within 1/4 inch (6.25mm) of top of res­ ervoir. Open caliper, bleed screw and allow caliper to Installation (1) Install the shoe and lining assemblies as...

  • Page 39: Removing Braking Disc And Hub

    SERVICE—BRAKES 5-37 fig. 3—Removing Caliper Lock and Spring (81 Remove flange nuts and lockwashers. Remove drive flange and discard gasket. <91 Straighten tang on lock ring and using Tool DD-1241-JD (Fig. 5i. remove outer lock nut. lock ring, inner lock nut and outer bearing Carefully slide hub fig.
  • Page 40 5-38 BRAKES—SERVICE off lock nut and retighten to 30 to 40 foot-pounds (40.6 to 54.2 N-m) while rotating hub and rotor. Back nut off 135° to is>0°. Assemble lock ring and outer lock nut. Tighten lock nut to 65 foot-pounds (88.1 N-m) minimum.

  • Page 41: Aw100, Pw100)

    SERVICE—BRAKES 5-39 ♦ ----------------------------------------------------------------------------------------------------------------------------------------------------------------- -- —-— inch (.025 to ,254mm). TAINED. Extreme care in the operation of rotor (8) Install new gasket on hub. Install drive flange, turning equipment is required. The collets, shafts Mockwashers and nuts. Tighten to 30 to 40 foot- and adaptors on the lathe and the bearing cups in the nds (40.6 to 54.2 N*mi.
  • Page 42 BRAKES—SERVICE ♦ SHOE REMOVAL PRIMARY SE5i?rl!i?^RY RETURN RcEJmM^ 100, Rear Brake Shoes (D1SO, AD AW 100, SPRING ANCHOR SPRING CABLE PD 100, PW100, W150) GUIDE PLATE SHOE (1) Using Tool C-3785, remove brake shoe return TAB <3) x SHOE RETAINERS. springs (Fig.
  • Page 43 ♦ SERVICE—BRAKES 5-41 PRIMARY SHOE ANCHOR PLATE RETURN SPRING ADJUSTER TAB OF ANTI­ CABLE RATTLE SPRING STRUT PRIMARY SHOE AND LINING NU245 Fig. 4—Removing or Installing Shoe Retainers, Springs and Nails (Right Rear) Fig. 5—Removing or Installing Parking Brake Strut (5) Spread anchor ends of primary and secondary and Spring (Left Rear) shoes and remove parking brake strut and spring...
  • Page 44 BRAKES—SERVICE ♦ Fig. 7—Removing or Installing Shoe Return Fig. 9-Removing or Installing Parking Brake Strut Springs (Left Rear) and Spring (Left Rear) should be limited to .005 inch (.127mm). When the number 2932524 or equivalent (Fig. 10). entire braking surface has been cleaned a final cut of (1) Install parking brake lever on inner side of sec­...
  • Page 45 ♦ SERVICE—BRAKES 5-43 PRIMARY SHOE ANCHOR PLATE (2) Attach parking brake lever to back side of sec­ RETURN ondary shoe, (Fig 9). SPRING (3) Place secondary and a primary shoe in their relative position on a work bench. TAB OF (4) Lubricate threads of adjusting screw and install ANTI-RATTIE it between primary and secondary shoes with star...

  • Page 46: General Information

    5-44 BRAKES—SERVICE ♦ BENDIX BX DUO-SERVO BRAKE (D200, D300, D400, W200, W300, W400) INDEX Page Page General Information ..........Brake Shoe Installation Service Procedure..........Rear............... Brake Drum Installation Brake Shoe Removal Rear................ Rear......Brake Drum Removal Cleaning and Inspection Rear................ Drum Refacing.....
  • Page 47 -SERVICE—BRAKES 5-45...
  • Page 48 5-46 BRAKES—SERVICE Fig. 5—Releasing Automatic Adjuster determine if the shoes are bent. The lining shou. show contact across the entire width, extending fro heel to toe. Shoes showing contact only on one sic should be replaced. Shoes having sufficient lining bi lack of contact at toe and heel should be measure for proper grind.

  • Page 49: Brake Drum Installation

    SUPPORT PLATES—BRAKES 5-V) PY1244 Fig. 8—Removing or Installing Shoe Assembly Fig. 7—Removing or Installing Shoe Hold (Rear) Down Springs (Rear) BRAKE DRUM INSTALLATION (1) Lubricate and assemble starwheel assembly, .ubricate guide pads on support plates iFig. 3) with Rear IOPAR Multi-Purpose lubricant Part...
  • Page 50 5-48 BRAKES—WHEEL CYLINDERS ------------------------------- --------- ----------------------------------------------------------------- —♦ retainer nuts to 35 foot-pounds (47.4 X-m). (4) Attach biake line to wheel cylinder and tighten to 95 inch-pounds (10.7 N-m). (5) Insert parking brake cable into support plate and attach cable to parking brake lever (if so equipped).
  • Page 51 WHEEL CYLINDERS—BRAKES 5-49 ♦ (1) In case of a leak, remove brake shoes (replace (31 Install wheel cylinder pistons in each end of if soaked with grease or brake fluid), boots, piston cylinder with recessed end of pistons facing open ^ wheel cylinder cups and wheel cylinder cup expan- ends of cylinder.

  • Page 52: General Information

    5-50 BRAKES—MASTER CYLINDER <£> iocknut PU623 Fig. 1—Brake Pedal Assembly and Linkage (Disassembled) MASTER CYLINDER (ALUMINUM) INDEX Page Page Bleeding Master Cylinder ........Master Cylinder Fluid Level ........Cleaning and Inspection ......... Master Cylinder Removal ........Disassembling Master Cylinder......Reassembling Master Cylinder....... General Information ..........

  • Page 53: Master Cylinder Removal

    ♦ MASTER CYLINDER—BRAKES 5-51 rSECONDARY SYSTEM COMPONENTS- PRIMARY SYSTEM — (REAR BRAKES) COMPONENTS (FRONT BRAKES) RESERVOIR DOUBLE LIP SECONDARY 8GDY TO RESERVOIR GROMMETS PISTON RETAINER SNAP RING PISTON PRIMARY PISTON RETAINER ASSEMBLY SECONDARY CHECK FLOW MASTER PRIMARY WASHER CYLINDER BODY PISTON RETAINER RETURN...
  • Page 54 5-52 BRAKES—MASTER CYLINDER require approximately 50 pounds pull. This will (1) Remove reservoir caps and empty brake fluid destroy the push rod retention grommet. from reservoir. 14i Remove nuts that attach master cylinder to (2) Position master cylinder in a vise. Grasp reser­ cowl panel.

  • Page 55: Cleaning And Inspection

    ♦ MASTER CYLINDER—BRAKES 5-53 remove secondary piston. If secondary piston sticks Primary Piston in bore of cylinder, use air pressure to force piston (1) Carefully wort- actumiary cup over rear end of out of cylinder. New cups must be installed at assem­ primary piston with larger lip of cup toward piston.
  • Page 56 BRAKES 5-54 —MASTER CYLINDER of springs. Do this several times until all air bubbles and adjust. (See Stop Lamp Switch Adjustment in are expelled (Fig. 9). “Service Adjustments”.) (4i Remove bleeding tubes from cylinder, plug outlets to prevent spillage and install caps. TESTING MASTER CYLINDER 151 Remove from vise and install master cylinder on vehicle as follows:...
  • Page 57 -MASTER CYLINDER—BRAKES 5-55 SERVICE PROCEDURES REMOVAL dry with compressed air. Wash the cylinder bore with clean brake fluid and inspect for scoring or pitting. Disconnect front and rear brake tubes from Master cylinder bore walls that have light scratches i,. .ter cylinder. or show signs of corrosion, can usually be cleaned (2) Remove bolt securing push rod to pedal link­...

  • Page 58: Brakes-Master Cylinder

    5-56 BRAKES—MASTER CYLINDER (4) Hold washer in position and install snap ring (5) Install tube seats, firmly (Fig. 6). BLEEDING Before installing master cylinder on vehicle, must be bled on bench as follows: (1) Clamp master cylinder in a vise and att: bleeding tubes Tool C-4029.
  • Page 59 HYDRAULIC SYSTEM CONTROL VALVES-BRAK 5-57 master cylinder is venting at both ports. To do this, necessary to pump up brakes rapidly and then hold remove master cylinder cover. Apply pedal lightly pedal down. Have an observer watch fluid in rear res­ and observe for a geyser of fluid squirting up in res- ervoir while pedal is raised.
  • Page 60 5-58 BRAKES-HYDRAULIC SYSTEM CONTROL VALVES —♦ WARNING TO REAR BRAKES TO FRONT BRAKE RY 601 Fig. 2—Combination Warning Switch/Hold Off Assembly—Typical Brass front (disc brakes) hydraulic system pressure until rear brake system will leave the front brake system still o: irative. rear drum brakes begin to apply.

  • Page 61: Check

    HYDRAULIC SYSTEM CONTROL VALVES—BRAKES 5-59 point it reduces the amount of pressure increase to Hold-Off Unit Operation the rear brakes according to a certain ratio. The hold-off valve section is used to hold off -'"'■^Thus, on light pedal applications, approximately pressure to the front disc brakes allow the rear drum '1 brake pressure will be transmitted to the front brake shoes to overcome the return springs and be­...
  • Page 62 Inside Diameter..7.775”(197mm) 8.86”(225mm) 8.86”(225mm) 8.80"(223mm) Ventilated Type ......Ventilated Ventilated Ventilated Thickness ....1.25”(31.75mm) 1.25"(31.75mm) 1.1- (30mm) 1.19”(30mm) Chrysler Caliper—Make....Chrysler Chrysler Bendix Type......Sliding Sliding Sliding Sliding 3.10"(78.7mm) Piston Diameter ..3.10”(78.7mm) 3.10”(78.7mm) 3.38”(85.8mm) Pistons Per Caliper ..
  • Page 63 (9.8-18.4) Brake Line Tube Nuts, 3/8 or 7/16 ........125-175 (15.3-21.5) 1/2 or 9/16 ........(162) Bottom attaching bolts ............. DISC BRAKE (CHRYSLER) (149) Adaptor Mounting Bolts D100-D200-AD100-PD100 ..... (203) W150-AW 100-PW100-W200 ..........(216) D200 H.D., D300, D400 ............(24.5) Retainer and Anti-Rattle Spring ..........
  • Page 64 1980 Chassis-Body-Electrical Service Manual / ’> ! '• ’ V> y;\ « -/^s / r<i rr^'Ti rp p^r^N liMair'MrtJj EFJ& New Yorker...
  • Page 65 Body CORPORATION Heaters and Air-Conditioning Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any Refer to Engine Performance obligations upon itself to install them on its products previous:/ manufactured.

  • Page 66: Master Cylinder Aluminum

    BRAKES ■ BRAKES CONTENTS Page Page BRAKE DISC (ROTOR)........POWER BRAKES .......... SERVICE ADJUSTMENTS......BRAKE EQUIPMENT APPLICATION..SERVICE DIAGNOSIS ........DISC BRAKES..........SPECIAL TOOLS .......... DRUM BRAKES ........... SPECIFICATIONS .......... HYDRAULIC SYSTEM CONTROL VALVES MASTER CYLINDER TIGHTENING REFERENCE......Aluminum ..........WHEEL CYLINDERS ........

  • Page 67: Master Cylinder Fluid Level

    BRAKES------------------------------------------- (I)* Jack up vehicle so all wheels are free to turn. driver’s seat to apply the brakes. Remove the plug from the rear adjustment slot in each brake support (21 Remove rear adjusting hole cover from brake plate to observe the adjuster star wheel. Then, to supports of vehicle.
  • Page 68 ------------------------------------------- B RAKES adapter C-4578) provides a convenient means of keep- this can cause an internal failure in the valve, result­ 'v"* the master cylinder full while pressurizing the ing in complete loss of front brakes. •aulic system for bleeding. (Complete bleeding of It should be noted that the pressure release valve tne dual master cylinder is important: See Bleeding stem is in its innermost position when there is no...
  • Page 69 BRAKES----------------------------------- - ------ the floor with light pedal effort. In a system with Inspection of Brake Hose and Tubing trapped air. pedal position is maintained at a constant Inspection of brake hose and tubing should be in­ pedal force, pedal will not fall away. cluded in all brake service operations and every second oil change (every oil change for vehicles used TEST FOR FLUID CONTAMINATION...
  • Page 70 BRAKES i? ■ ■ » V, , ■...
  • Page 71 BRAKES- — . « © ■O • o < €>!<$> <§><§>'<$><...

  • Page 72: Stop Lamp Switch Adjustment

    BRAKES (1) Using Tool C-3478-A, or equivalent, cut off dam- STOP LAMP SWITCH ADJUSTMENT ,.aeoH seat or damaged tubing (Fig. 6). The stop lamp tor stop lamp speed control) switch Ream out any burred or rough edges showing and mounting bracket assembly is attached to the -on inside edges of tubing.

  • Page 73: Service Diagnosis

    BRAKES SERVICE DIAGNOSIS INDEX Page Page Basic Diagnosis Guide ..........Miscellaneous Conditions ........... Brake Noise ..............Power Brake ..............Hydraulic System (Actuation) ........Wheel Brake ..............GENERAL INFORMATION Refer to “Symptoms” column in the Basic Diagnosis the indicated chart for the symptom diagnosis. Guide to identify brake related problem.
  • Page 74 ■ BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS CHECK WARNING LIGHT (IGNITION ON) PU56...
  • Page 75 5-10 BRAKES BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS PH634D...
  • Page 76 BRAKES 5-11 BRAKE CHART 4 BRAKE NOISE DIAGNOSIS “INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED "WAYS" OF CALIPER AND ADAPTER. •••MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. PU57 BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED OR REDUCED BY ROTATION DRUM (REAR) TWO PH632D STUDS ON AXLE FLANGE.
  • Page 77 5-12 DRUM BRAKES DRUM BRAKES INDEX Page Page Drum Refacing Recommendations ......Brake Drum Removal .. General Information ............Brake Shoe Removal ... Service Diagnosis ............Brake Drum Installation Special Tools ..............Brake Shoe Installation Cleaning and Inspection GENERAL INFORMATION All drum brake applications are two shoe, internal lower ends of the brake shoes are connected by a expanding brakes with application adjusters.

  • Page 78: Drum Brakes

    DRUM BRAKES 5-13 SPECIAL TOOL PRIMARY SHOE PRIMARY SEdC°"°ARY REMOVING RETURN RETURN R.EJURN INSTALLING) SPRING SPRING ANCHOR, SPRING CABLE SECONDARY GUIDE PLATE SHOE RETURN SHOE ANTI-RATTLE SPRING TAB ',3) > SPRING SHOE RETAINERS. SPRING AND NAIL ASSEMBLIES ANTI- RATTLE SPRING STRUT PARKING LEVER...
  • Page 79 5-14 DRUM BRAKES SOCKET »*I<S SUPPORT SCREW THREADS PB510A Fig. 5—Adjuster Screw Assembly (3) Slide parking brake strut behind hub and into slot in parking brake lever. Slide anti-rattle spring over free end of strut (Fig. 8). On ten inch brakes, SHOE CONTACT NRI07A be sure spring tab is pointing rearward and up on...

  • Page 80: Brake Drum Installation

    ■------- ----------------------------------------------------------------------------------- --------MASTER CYLINDER (ALUMINUM) 5-15 over anchor, using Tool C-3785. (Be sure cable guide over pivot pin. Slide lever slightly rearward to lock in •>mains flat against shoe web and that secondary position. ring overlaps primary) (Fig. 1). Using pliers, (9) Using Tool C-4070, install shoe retaining nails, squeeze ends of spring loops (around anchor) until...

  • Page 81: Master Cylinder Removal

    5-16 MASTER CYLINDER (ALUMINUM) RESERVOIR T SECONDARY SYSTEM COMPONENTS -r- PRIMARY SYSTEM — COVER (REAR BRAKES) COMPONENTS (FRONT BRAKES) RESERVOIR GASKET DOUBLE LIP SECONDARY SEAL PRIMARY BODY TO RESERVOIR GROMMETS PISTON RETAINER SNAP RING PISTON RETAINER PRIMARY PISTON ASSEMBLY SECONDARY CHECK FLOW MASTER...

  • Page 82: Cleaning And Inspection

    MASTER CYLINDER (ALUMINUM) 5-17 ■ PR293 Fig. 5—Removing or Installing Snap Ring Fig. 2-Separating Reservoir from Master Cylinder Housing bly if air pressure is used (Fig. (3) Remove master cylinder housing to reservoir (8) Remove rubber cups from pistons, after noting grommets (Fig.

  • Page 83: Bleeding Master Cylinder

    5-18 MASTER CYLINDER (ALUMINUM) (6) Install housing reservoir grommets in master dence'of these conditions exist, replace the master cylinder housing. cylinder. DO NOT HONE. If master cylinder pistons are badly scored or cor­ (7) Place master cylinder in a vise. Lubricate res­ roded, replace them with new ones.
  • Page 84 ■ HYDRAULIC SYSTEM CONTROL VALVE 5-19 (2) Install and tighten attaching nuts to 200 only occur in the secondary chamber and so to deter­ ± h-pounds (22.59 3.38 N-m). mine if the primary vent port is open, it will be ±...
  • Page 85 HYDRAULIC SYSTEM CONTROL VALVE 5-20 Fig. 1 —Combination Warning Switch/Hold Off I Proportioning Valve Assembly (Sectional View) pressure. Under light pedal application, the valve al­ Proportioning Unit Operation The proportioning valve section operates by trans­ lows full hydraulic pressure to rear brakes. mitting full input pressure to the rear brakes up to a There is only one valve assembly in each vehicle, certain point, called the split point, and beyond that...
  • Page 86 HYDRAULIC SYSTEM CONTROL VALVE 5-21 VALVE APPLICATION CHART Hold-Off Split Brake Hydraulic Cut-In Point ‘Identification Car Line Type Valve Type (PSI) (PSD/Slope B,F,G,H,N Sedan Disc W/P/H 300/3 Black B,F,G,H,N Wagon Disc W/P/H 300/2.3 White H,N Taxi Disc W/P/H 300/2.3 Yellow H,N Police and Sedan Wagon Disc W/P/H...

  • Page 87: Wheel Cylinders

    5-22 WHEEL CYLINDERS-------------------------- inlet gauge and check the reading on the outlet fluid'pressure to the rear brakes is above the reduc­ gauge. If the inlet and outlet pressures do not agree tion ratio for the rear line pressure and that a mal­ with the values on the following chart, replace the function has occurred within the proportioning valve valve.
  • Page 88 WHEEL CYLINDERS 5-23 REAR —HOUSING PISTON PUSH ROD PRESS-ON BOOT EXPANDERS PISTON 5/16'' BLEED SCREW PUSH ROD PF449A Fig. 2—Rear Wheel 'Under, 10 and 11 Inch Brakes clean brake fluid or alcohol; clean thoroughly REMOVING BRAKE SUPPORT blow dry with compressed air. Inspect cylinder bore (7-1/4 INCH AXLE) and piston for scoring and pitting.

  • Page 89: Adjusting Parking Brake

    5-24 PARKING BRAKES---------------------------- (2) Insert rear axle shaft and retainer into hous­ (6) Install brake drum and wheel. Adjust and bleed brakes. ing and install axle retainer nuts and washers. Removing and installing brake support assemblies (31 Attach brake tube to wheel cylinder. (4) Insert parking brake cable into support plate on 8-1/4 inch axles following the same general pro­...

  • Page 90: Parking Brakes

    PARKING BRAKES 5-25...
  • Page 91 5-26 PARKING BRAKES-...
  • Page 92 PARKING BRAKES 5-27 as a guide for cable installation). (7i Work cable and housing assembly up through floor pan. Disconnect the guide wire E,J,S,T,X only) and leave in place for installation of new front cable. INSTALLING PARKING BRAKE FRONT CABLE All Models fl) (E,J,S,T,X only).
  • Page 93 5-28 POWER BRAKES POWER BRAKES INDEX Page Page General Information ............. Power Brake Vacuum Hose......... Power Brake Assemblies Service Diagnosis ............B,E,F,G,H,J,N,S,T,X Models ......... Service Procedures............GENERAL INFORMATION (Figs. 3, 4 and 5). The power brake unit mounts on the engine side of the cowl panel and is externally connected to the brake This master cylinder contains all of the standard brake master cylinder elements, except for a push...

  • Page 94: Power Brakes

    POWER BRAKES 5-29 ■ Fig. 1—Power Brake Actuation (6) Rotate linkage as necessary and remove power brake unit from vehicle. Fig. 3—Removing Retainer Clip from Pedal Pin (7) Remove pivot bushings and sleeve for reuse. INSTALLING POWER BRAKE UNIT (1) Rotate linkage as necessary and position power brake booster onto dash panel.
  • Page 95 5-30 POWER BRAKES DASH PANEL (REFERENCE) VACUUM E, J, S, T, X MODELS-BENDIX POWER BRAKE (9.5 Inch Tandem Diaphragm Bendix) SERVICE PROCEDURES en nuts to 200-250 inch-pounds. REMOVING POWER BRAKE UNIT (2) Using lubriplate or equivalent coat the bearing surface of bolt that connects power brake pedal link (1) Disconnect master cylinder from power brake with brake pedal linkage.

  • Page 96: Special Tools

    DISC BRAKES 5-31 ■ VACUUM HOSE VACUUM HOSE THROTTLE CONTROL ROD (FLEXIBLE TYPE) (PREFORMED) CONNECTOR ASSEMBLY 4> 4 NUT AND CLAMP WASHER ASSEMBLY VACUUM HOSE (FLEXIBLE TYPE) CLAMP INTAKE MANIFOLD 225 CUBIC INCH ENGINE ALL INTAKE MANIFOLD VACUUM CONNECTOR HOSE NIPPLES MUST BE ORIENTED IN REAR 180’...
  • Page 97 5-3£ DISC BRAKES--------------------------------- With disc brakes, brake application is immediate wall. A moulded rubber dust boot installed in a groove and braking response is directly proportional to pedal in the cylinder bore and piston keeps contamination effort. Drum brake response occurs after piston travel, from the cylinder wall and piston.

  • Page 98: Disc Brakes

    DISC BRAKES 5-33 ■ PISTON BRAKE FLUID WHEEL STUD SPINDLE BRAKING DISC NUJD Assembly-Sectional Fig. —Disc Brake...

  • Page 99: Service Checks

    5-34 DISC BRAKES mating surfaces are clean and free from nicks and burrs. New seal washer(s) should be used and all con­ nections should be properly made and tightened. Dou­ ble wall steel tubing should always be used for re­ placement.

  • Page 100: Brake Shoes

    ■ DISC BRAKES 5-35 SERVICE PROCEDURES with wire brush, reinstall “0" ring. SLIDING caliper Inspect braking surfaces of disc. BRAKE SHOES Installation (1) Slowly and carefully push piston back into bore Removal until it is bottomed. Watch for possible master cylin­ (1) Raise vehicle on a hoist or jackstands.
  • Page 101 5-36 DISC BRAKES ANTI-RATTLE SPRING PISTON ' PFS05D Fig. 6—Sliding Caliper Assembly Exploded View recess of caliper. No free play between CAUTION: Fig. 10—Bending Outboard Shoe Retaining Flange brake shoe flanges and caliper fingers (Fig. 9) should exist (which might cause brake shoe rattle). If free BOOT SLIDE OVER TH ABOARD SHOE.

  • Page 102: Disassembling Caliper

    DISC BRAKES 5-37 (8) Install wheel and tire assemblies. Tighten stud DISASSEMBLING CALIPER ‘s in proper sequence (Fig. 19), skipping every ier nut until all 5 are torqued to 85 foot-pounds. (1) To remove piston, support caliper assembly on Install wheel covers. This is very important.

  • Page 103: Cleaning And Inspection

    5-38 DISC BRAKES However, bores that have deep scratches or scoring should be honed (Fig. 15), using Tool C-4095, provid­ ing the diameter of the bore is not increased more than .001 inch. If the bore does not clean up within this specification, a new caliper housing should be in­...

  • Page 104: Installing Caliper

    DISC BRAKES 5-39 INSTALLING CALIPER Examine lining for wear, damage or fluid contam­ ination; if its condition is found satisfactory it may be reused. If not usable both front brakes must be relined with new lining. If old lining is to be reused, be sure linings are installed in their original position.
  • Page 105 5-40 BRAKE DISC (ROTOR) (11) Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. BLEEDING DISC BRAKES The disc brake hydraulic system can be bled manu­...
  • Page 106 ■----------------------------------------------------------------------------------------- BRAKE DISC (ROTOR) 5-41 Thickness variation in a disc can also result in pedal tion can be caused by extreme heat and abuse of the Isation, chatter and surge due to variation in brake brakes, output when disc section is uneven. Dishing or distor- SERVICE PROCEDURES should be made in conjunction with runout.

  • Page 107: Removing Braking Disc And Hub

    5-42 BRAKE DISC (ROTOR) “Removing Caliper” this Group, (but do not disconnect heavy scoring or warping is evident, the disc must be refinished or replaced (See Refinishing (Refacing) brake line). Suspend caliper from wire hook or loop to Braking Disc). If cracks are evident the hub and disc avoid strain on flexible hose.

  • Page 108: Specifications

    SPECIFICATIONS 5-43 Refaeing Braking Disc The use of a double straddle cutter which machines Rotors do not have to be refaced every time a disc both sides of the disc at the same time is highly recom­ ^rake is relined. If the rotor surface is deeply scored mended.
  • Page 109 5-44 TIGHTENING REFERENCE 125"W x .120" Piston Seal—Moulded Rubber— 125"W x .120" Square Section ....... Radial Radial Piston Dust Boot—Moulded Rubber External External DISC Type—All Cast Iron ......Ventilated Ventilated 10.98" Diameter—Outside......11.75" 6.975" —Inside ....... 7.755" Runout—Maximum Allowable T.I.R. .004"...
  • Page 110 SPECIAL TOOLS—BRAKES 5-45 « C-4029 PU5S8B...
  • Page 111 Chassis Omni Horizon Body Aries Electrical Service Manual...

  • Page 112: Group Index

    GROUP INDEX K£ — Introduction Lubrication and Maintenance Suspension Foreword rill [§J This Service Manual has been prepared with the Brakes latest servicing information available at the time of publication. It is subdivided into various group cate­ gories and each section contains diagnosis, disassem­ 0 Clutch bly, repair, and installation procedures along with complete specifications and tightening references.

  • Page 113: Service Adjustments

    —BRAKES---------------------------------------- 5 -1 BRAKES CONTENTS Page Page BRAKE DISC (ROTOR)......SERVICE ADJUSTMENTS......DISC BRAKES.......... SERVICE DIAGNOSIS....... DRUM BRAKES......... SPECIFICATIONS........MASTER CYLINDER........TIGHTENING REFERENCE....... PARKING BRAKES........WHEEL CYLINDERS......... POWER BRAKES........SERVICE ADJUSTMENTS INDEX Page Page Adjusting Rear Service Brakes Master Cylinder Fluid Level ........Bleeding Brake System..

  • Page 114: Master Cylinder Fluid Level

    BRAKES TEST FOR FLUID CONTAMINATION Repeat adjustment at other wheel. Install adjusting hole covers in brake supports. Indications of fluid contamination are swollen or Adjust parking brake. deteriorated rubber parts. Swollen rubber parts indicate the presence of pe- MASTER CYLINDER FLUID LEVEL ' troleum in the brake fluid.
  • Page 115 BRAKES Place 4.76 mm (3/16 in.) plug of gauge down in Inspection Inspection of brake hoses should be performed end of tubing. Swing compression disc over gauge and whenever the brake system is serviced and every center tapered flaring screw in recess of disc. Screw in 7,500 miles or 12 months, whichever comes first until plug gauge has seated on jaws of flaring tool.
  • Page 116 BRAKES 5-4-...
  • Page 118 BRAKES ADJUSTMENT— CARUNES P, D BRAKE PEDAL BRACKET The stop lamp switch for Carlines P, D incorporates ASSEMBLY a new self adjusting feature. If adjustment or re­ placement is required, proceed as follows: Install the switch in the retaining bracket and push the switch forward as far as it will go.
  • Page 119 BRAKES BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. COND. ACTUATION POWER NOISE WHEEL BRAKES BRAKE WARNING LIGHT "ON" EXCESSIVE PEDAL TRAVEL PEDAL GOES TO FLOOR STOP LIGHT "ON" WITHOUT BRAKES ALL BRAKES DRAG REAR BRAKES DRAG GRABBY BRAKES SPONGY BRAKE PEDAL...
  • Page 120 -------------- BRAKES----------- BRAKE CHART 1 DIAGNOSIS SHEET 2 OF 5 RB835...
  • Page 121 BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS SHEET 3 OF 5 RB835...
  • Page 122 BRAKES 5-10 BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS SHEET 4 OF 5 RB835...
  • Page 123 BRAKES 5-11 BRAKE CHART 4 BRAKE NOISE DIAGNOSIS ••'MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED OR REDUCED BY ROTATING DRUM (REAR) TWO STUDS ON AXLE FLANGE. SHEET 5 OF 5 RB835...

  • Page 124: General Information

    DRUM BRAKES 5-12 DRUM BRAKES INDEX Page Page Drum Refacing............Brake Drum and Shoe Removal....... General Information ..........Brake Drum and Shoe Installation......Service Diagnosis ..........Cleaning and Inspection .......... Service Procedures ........... GENERAL INFORMATION Brake shoe return springs are located behind the Rear wheel brakes (Figs.
  • Page 125 DRUM BRAKES 5-13 l^g) FRONT RETURN CYLINDER BOOT "-----------------BRAKE SPRING (PRESS FIT) CYLINDER RETURN SPRING PARKING BRAKE LEVER ADJUSTER SCREW? ASSEMBLY III . HOLD DOWN HOLD DOWN 'SPRING PIN SPRING i TRAILING SHOE AND LINING SUPPORT PARKING LEADING SHOE BRAKE CABLE LINING ANCHOR PLATE SHOE TO ANCHOR...
  • Page 126 5-14 DRUM BRAKES FRONT Fig. 6. Removing Shoe to Anchor Springs Lubricate shoe tab contact areas (six places in Fig. Drum Refacing 13) on support plate and web ends of brake shoes that Measure drum runout and diameter. If not to contact anchor plate, using MOPAR Multi-Purpose specification, reface drum.
  • Page 127 DRUM BRAKES 5-15 . R571 Fig. 10. Removing Leading Brake Shoe Fig. 13. Shoe Contact Areas on Support Plate ADJUSTER NUT PU205A Fig. 11. Adjuster Screw Assembly Fig. 12. Maximum Drum Diameter Identification...
  • Page 128 DRUM BRAKES stall trailing shoe and lever assembly at same time as Installation engaging spring end in support. Position end of shoe Install leading shoe return spring in position on under anchor plate (Fig. 16). shoe. Install leading shoe at same time as engaging Spread shoes and install adjuster screw assembly.
  • Page 129 DRUM BRAKES 5-17 FRONT outer bearing, washer and nut. Tighten adjusting nut to 27-34 N-m (240-300 in .lbs.) Compress parking brake cable housing spring while rotating brake drum. slightly to expose cable, then slide into position in Back off adjusting nut with wrench to completely parking brake lever.
  • Page 130 DISC BRAKES 5-18 DISC BRAKES INDEX Page Page Assembling Caliper........... General Information ..........Bleeding Disc Brakes......Routine Maintenance ..........Service Precautions..........Brake Shoe Installation ........... Service Diagnosis ............ Brake Shoe Removal M, Z........Service Procedures ..........Brake Shoe Removal P, D........Specifications ............
  • Page 131 DISC BRAKES 5-19 The wheel, tire, hub and braking disc assembly be removed as an assembly. The caliper as­ cannot sembly must be removed before removing the hub and braking disc assembly. (See Figs. 4, 5). Fig. 2. Disc Brake Caliper Mounting The square cut rubber piston seal is located in a ichined groove in the cylinder bore and provides a nydraulic seal between the piston and the cylinder...
  • Page 132 DISC BRAKES ROUTINE MAINTENANCE—48 000 Kilometres SERVICE PROCEDURES (30,000 Miles) BRAKE SHOES Check Brake Lines and Hoses Raise all four wheels. Removal-Carlines M, I Remove the front wheel and tire assemblies and in­ Raise vehicle on jackstands or centered on a hoist. spect the braking disc and caliper assemblies.
  • Page 133 -DISC BRAKES- -5-21 Fig. 7. Removing or Installing Caliper- Carlines M, Z Fig. 9. Removing or Installing Braking Disc OUTBOARD SHIELD PAD AND LINING INBOARD PAD AND LINING ADAPTER PR742B Fig. 8. Removing or Installing Outboard Pad Fig. 10. Removing or Installing Inboard Pad and Lining and Lining...
  • Page 134 DISC BRAKES 5-22 Loosen, no not remove caliper guide pins until Removal—Carlines P, D caliper is free. Remove guide pins only if bushings or Raise vehicle on jackstands or centered on a hoist. sleeves are to be replaced. Remove front wheel and tire assemblies. Lift caliper out and away from braking disc (Fig.

  • Page 135: Disassembling Caliper

    DISC BRAKES 5-23 Lift the outboard shoe and lining from the adapter Cleaning and Inspection Check for piston seal leaks (brake fluid in and (Fig. 14). around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored).
  • Page 136 DISC BRAKES 5-24- BLEEDER SCREW CAP CALIPER PIN ------------ *© BLEEDER SCREW- ANTI-RATTLE SPRING DISC BRAKE PADS PR744D Fig. 15. Disc Brake Caliper—Carlines M, Z (Disassembled View) Fig. 16. Disc Brake Caliper—Carlinet P, D (Disassembled View)

  • Page 137: Assembling Caliper

    DISC BRAKES -5-25 Bores that have deep scratches or scoring should Black stains on the steel piston are caused by the be honed, using Tool C-4095, providing the diameter piston seal and will do no harm, carlines M, Z. of the bore is not increased more than .0254 mm (.001 When using Hone C-4095, coat the stones and bore inch).
  • Page 138 5-26 DISC BRAKES Dip new piston seal in clean brake fluid and install and Tool C-4682 for carlines M, Z with C-4171 handle, in groove in bore. Seal should be positioned at one drive boot into counterbore. (Fig. 23). area in groove and gently worked around the groove, using fingers until properly seated.

  • Page 139: Bleeding Disc Brakes

    DISC BRAKES 5-27 Be sure flanges extend over caliper casting evenly on both sides. Before installing caliper assembly on vehicle, in­ spect braking disc. Conditions as described in “Checking Braking Disc for Runout and Thickness’’ paragraph. Install brake hose to caliper using new seal wash­ ers.
  • Page 140 BRAKE DISC (ROTOR) 5-28 BRAKE DISC (ROTOR) INDEX Page Page Refacing Braking Disc ..........Checking Braking Disc for Runout......Removing Braking Disc .......... General Information ..........Resurfacing Braking Disc ........Installing Braking Disc ........... Service Procedures..........GENERAL INFORMATION Excessive wear and scoring of the disc can cause Any servicing of the braking disc requires extreme temporary improper lining contact if ridges are not care to maintain the braking disc within service tol­...

  • Page 141: Service Procedures

    BRAKE DISC (ROTOR) 5-29 SERVICE PROCEDURES on hub with chalk marks 180 degrees apart (Fig. 4). CHECKING BRAKING DISC FOR RUNOUT Finally, recheck runout of disc to see if runout is now AND THICKNESS within specifications .127 mm (.005"). “On vehicle, braking disc (rotor) runout” is the com­ If runout is in excess of specifications, install a new bination of the individual runout of the hub face and disc or reface disc, being careful to remove as little as...
  • Page 142 -BRAKE DISC (ROTOR) - 5-30 possible from each side of disc. Remove equal amounts REMOVING BRAKING DISC from each side of disc. Do not reduce thickness below minimum thickness 10.95 mm (.431 in.) M, Z models, (1) Raise vehicle on hoist or jackstands. Remove and 22.4 mm (.882 in.) for P and D models cast into wheel and tire assembly.
  • Page 143 BRAKE DISC (ROTOR) 5-31 REFINISHING (REFACING) BRAKING DISC Resurfacing Braking Disc This operation can be used when the disc surface is rusty or has lining deposits. A sanding disc attachment will remove surface contamination without removing much material. It will generally follow variations in thickness which are in the disc.
  • Page 144 WHEEL CYLINDERS 5-32 WHEEL CYLINDERS INDEX Page Page Installing Wheel Cylinders Assembling Wheel Cylinders ... Removing Brake Supports Disassembling Wheel Cylinders Removing Wheel Cylinders General Information ....Service Procedures..Installing Brake Supports..GENERAL INFORMATION The piston boots (Fig. 1) are of the press-on type and prevent moisture from entering the wheel cylin­...
  • Page 145 5-33 WHEEL CYLINDERS Slide piston into cylinder bore and press in to re­ move opposite piston, cups, and spring with cup ex­ panders from cylinder bore. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; clean thoroughly and blow dry with compressed air.
  • Page 146 5-34 PARKING BRAKES REMOVING BRAKE SUPPORT ASSEMBLY INSTALLING BRAKE SUPPORT ASSEMBLY Back off parking brake adjusting nut to provide Insert parking brake cable and housing into support slack in cable. plate. With wheel and brake drum removed disconnect Install support plate and spindle on to rear suspen­ tube from wheel cylinder.
  • Page 147 PARKING BRAKES...
  • Page 148 PARKING BRAKES 5-36...
  • Page 149 PARKING BRAKES 5-37 ^(g) STALLING PARKING BRAKE REAR CABLE INSTALLING PARKING BRAKE FRONT CABLE Insert brake cable and housing inner end through Insert cable housing retainer into hole in floor pan trailing arm holes and cable bracket on cross member. (Figs.
  • Page 150 5-38 MASTER CYLINDER MASTER CYLINDER INDEX Page Page Bleeding Master Cylinder........Master Cylinder Fluid Level ........Cleaning and Inspection ......... Master Cylinder Removal ........Disassembling Master Cylinder......Reassembling Master Cylinder ......General Information ..........Testing Master Cylinder.......... Installing Master Cylinder........Service Procedures..........

  • Page 151: Master Cylinder Removal

    5-39 MASTER CYLINDER SERVICE PROCEDURES from under instrument panel. Pull stop lamp switch MASTER CYLINDER REMOVAL out of way to prevent switch damage. Power Brake Equipped Pull brake pedal backward sharply to disengage Disconnect primary and secondary brake tubes push rod from master cylinder piston. This will de­ from master cylinder.

  • Page 152: Cleaning And Inspection

    5-40 MASTER CYLINDER PISTON Fig. 6. Removing Snap Ring Install check flow washer. move secondary piston. If it sticks in bore of cylin­ Carefully place primary cup, with lip facing away der, use air pressure to force piston out of cylinder. from piston, on piston.

  • Page 153: Bleeding Master Cylinder

    MASTER CYLINDER 5-41 |^g) unit, align push rod with master cylinder piston. Install attaching nuts and tighten to specification. Connect brake tubes and tighten to specification. Bleed brakes. Manual Brake Equipped Install the push rod boot on the push rod. Install a new push rod grommet onto push rod.
  • Page 154 M, Z models equipped with the 2.2L engine use a Vehicles equipped with the Chrysler 2.2L engine use power brake unit, and vacuum hose connections as a charcoal filter in the hose between the booster and shown in (Fig.
  • Page 155 POWER BRAKES 5-43 RB107A Fig. 3. Power Brake Unit/Vacuum Hose Connections Carlines M, Z SERVICE PROCEDURES Install and tighten four mounting nuts to 23- REMOVING POWER BRAKE UNIT 28 Newton metres (200-250 inch-pounds). Remove nuts attaching master cylinder to power Carefully position master cylinder on power brake unit.
  • Page 156 5-44- -SPECIFICATIONS- SPECIFICATIONS Metric DRUM BRAKE U. S. Customary Type ..... Leading Trailing Single Anchor Diameter-Standard ............200mm 7.87 in. Width—Standard ............. 30mm 1.18 in. Lining Leading—Length & Thickness—Standard....203.2mm x 4.76mm 8 in. x 3/16 in. Trailing—Length & Thickness—Standard....203.2mm x 4.76mm 8 in.
  • Page 157 REFERENCE------------- ------------- 5-45 M, Z PEDAL ratio 8.5:1 Manual....7.5:1 Power ....5.1:1 3.5:1 booster Bendix Make ....Bendix 228.6mm (9 in.) Size ..... 230mm (9.05 in.) Single Type ....Single 1779 N. (400 lbs.) Boost @ 20" Hg. 2670 N. (600 lbs.) Mounting Studs .

  • Page 158: Special Tools

    SPECIAL TOOLS 5-46...
  • Page 159 Truck 150-450 1931 Ramcharger Service Trailduster Manual...
  • Page 160 Body CORPORATION Heaters and Air-Conditioning~^P| Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured. Emissions Control Systems Litho in U.S.A.
  • Page 161 BLEEDING BRAKE SYSTEM....... HYDRAULIC SYSTEM CONTROL VALVES . BRAKE ADJUSTMENT DUO-SERVO ..MASTER CYLINDER INTERNAL LEAK BRAKE HOSE AND TUBING....... CHECK ............DISC BRAKE—CHRYSLER (D150, D250, MASTER CYLINDER 0350, D450, AD150, PD150)....ALUMINUM..........DISC BRAKE—BENDIX (W350, W450 & CAST IRON..........
  • Page 162 BRAKES BASIC DIAGNOSIS GUIDE Chart 1 Chart 2 Chart 3 Chart 4 Chart 5 Misc. Cond. Actuation Power Noise Wheel Brak Symptom Brake Warning Light “ON" Brake Chatter (Rough) Surge During Braking Noise During Braking Pull to Right or Left Premature Rear Lockup Rear Brakes Drag Brakes Drag—ALL...

  • Page 163: Check

    BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS CHECK WARNING LIGHT (IGNITION ON) LIGHT "OFF" LIGHT "ON" INDICATING MALFUNCTION APPLY PARKING BRAKE AND CHECK WARNING LIGHT DRAGGING ON-LIGHT OK 1 BRAKES ELECTRICAL REPAIR ON LIGHT CIRCUIT SLOWLY APPLY FORCE _____ _ TO PEDAL UP TO 50 LBS.;...
  • Page 164 BRAKES BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS...
  • Page 165 «■ BRAKES BRAKE CHART 4 BRAKE NOISE DIAGNOSIS “INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED "WAYS" OF CALIPER AND ADAPTER. •••MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED ROTATION DRUM (REAR) TWO Of? REDUCED B PH 632E...

  • Page 166: Hydraulic Brake System

    BRAKES—HYDRAULIC SERVICE PROCEDURES into a small clear glass bottle. Separation of the fluid HYDRAULIC BRAKE SYSTEM into distinct layers will indicate mineral oil content. Servicing the hydraulic system is chiefly a matter of Be safe and discard old brake fluid that has been bled adjustments, replacement of worn or damaged parts from the system.
  • Page 167 ♦------------------------------------------------------------------------------------------------------------------------------- —- —--------------------HYDRAULIC—BRAKES falling into the master cylinder reservoir when the Pedal Bleed: This method of bleeding is not af­ cover is removed. fected by the hold-off valve, as fluid pressures are in (1) Check brake master cylinder to be sure boot is excess of 165 psi (1137.6 kPa).
  • Page 168 BRAKES—HYDRAULIC ♦ felt when road wheel is rotated. In a trapped air condition, the brake warning light will go off when brake pedal is released. (5) For application type adjuster (Fig. 2), insert ad­ If warning light does not go off after you release justing Tool C-37C4, into star wheel of adjusting ^"■ake pedal, the master cylinder is bad or hydraulic screw.

  • Page 169: Brake Hose Inspection

    HYDRAULIC—BRAKES ♦---------------------------------------------------------------------------------------------------- -—— all brake service operations. automatic adjusters do not function properly, the re­ spective drum must be removed for adjuster serv­ Always use factory recommended hose to insure quality, correct length and superior fatigue life. Care icing. should be taken to make sure that the tube and hose .EEL STUD TIGHTENING mating surfaces are clean and free from nicks and burrs.
  • Page 170 (11) Clean seat and tube of any lubricant before (7) Place proper sized plug of gauge “A” down in connecting to hydraulic system. DISC BRAKE-CHRYSLER (D150, D250, D350, D450, AD 150, PD 150) INDEX Page Page Assembling Caliper...........
  • Page 171 DISC (SLIDING CALIPER)—BRAKES 5-11 a hydraulic seal between the piston and the cylinder CALIPER wall (Fig. 3). The adaptor is mounted to the steering knuckle by two special nylock bolts (Figs. 1 and 3). A moulded rubber dust boot installed in a groove RETENTION ,u the cylinder bore and piston keeps contamination FLANGE...
  • Page 172 5-12 BRAKES—DISC (SLIDING CALIPER) PISTON •BRAKE FLU WHEEL STUD- SPINDLE BRAKING DISC- Fig. 3—Disc Brake Assembly (Sectional)
  • Page 173 ♦ DISC (SLIDING CALIPER)—BRAKES 5-12 Fig. 5—Piston Seal Function For Automatic Adjustment inspected at this time and replaced if necessary). caliper assembly must be removed in order to inspect the inner wheel bearings. (Refer to ‘‘Brake Shoe Re­ moval” paragraph). Do not get oil or grease on the braking disc or lin­...

  • Page 174: Brake Shoe Installation

    5.14 BRAKES-DISC (SLIDING CALIPER) Fig. 6—Removing or Installing Caliper INBOARD SHOE mating surfaces of the abutments on the caliper and PF854A adaptor. If corroded or rusty, clean surfaces with wire Fig. 8—Removing or Installing Shoe brush. Inspect braking surfaces of disc. shoe after above modification, if necessary, by snap­...

  • Page 175: Disassembling Caliper

    ♦ DISC (SLIDING CALIPER)—BRAKES 5-15 (7) Check and refill master cylinder reservoirs (if necessary) with DOT 3 brake fluid as required. It should not be necessary to bleed the system after shoe and lining removal and installation. However, if a firm pedal cannot be obtained bleed the brake sys­ tem as described in "Bleeding the Brake System”...

  • Page 176: Assembling Caliper

    5-16 BRAKES—DISC (SLIDING CALIPER) protector ]'aws. Caution: Excessive vise pressure will cause bore distortion and binding of piston. CALIPER (6) Remove dust boot using suitable tool. (7) Using a small, pointed, wooden or plastic stick, work piston seal out of its groove in piston bore (Fig. Discard old seal.

  • Page 177: Installing Caliper

    ♦ —DISC (SLIDING CALIPER)—BRAKES 5-17 (3) Slowly slide caliper assembly into position in adaptor and over disc. Align caliper on machined ways of adaptor. Be careful not to pull the dust boot from its groove as the piston and boot slide over the inboard shoe.

  • Page 178: General Information

    ♦ 5-18 BRAKES—DISC (ROTOR) BRAKING DISC (D150, D250, D350, D450, ADI 50, PD150) INDEX Page Page Checking Braking Disc for Runout......Refacing Braking Disc ..........General Information ..........Removing Braking Disc ........... Inspection Diagnosis..........Resurfacing Braking Disc ........Installing Braking Disc (and Hub)......GENERAL INFORMATION Any servicing of the brake disc requires extreme the lining and cause noise and chatter.

  • Page 179: Removing Braking Disc And Hub

    DISC (ROTOR)—BRAKES 5-19 stands. Remove wheel cover and wheel and tire as­ from edge of disc. If thickness measurements exceed specifications, disc should be removed and resurfaced sembly. or a new disc and hub assembly installed (Fig. 1). (2) Remove caliper assembly as described under (4) Light scoring and/or wear is acceptable.
  • Page 180 (.381-.457) D250 Extra, 1.170/1.190 .001 .005 15-80 (29.71/30.22mm) (.025mm) D3, D4 (.127mm) (.381-.457) DISC BRAKE-CHRYSLER (W150, W250, AW150, PW150) INDEX Page Page Assembling Caliper........... Hold-Off Valves............Brake Roughness............Installing Caliper ............Brake Shoe Installation ........... Removing Caliper from Vehicle........ Brake Shoe Removal..........
  • Page 181 ------------------------------------------------------------------------- ------------------------------ SERVICE—BRAKES 5-21 The cast iron braking disc has cooling fins or lou­ wiping lip that prevents contamination in the bore vres that are cast integrally between the two area. brake pedal depressed, hydraulic machined braking surfaces (Fig. 2). iVhen the wheel is in motion, the rotation of the pressure is applied against the piston.

  • Page 183: Service Brakes

    SERVICE—BRAKES 5-23 ♦ stand unused for periods of time in areas of high hu­ midity or salt air may incur rust on the disc which could cause a temporary brake surge and roughness. Normally however, this condition should correct it­ self after a short period of usage.
  • Page 184 5-24 BRAKES—SERVICE ♦ Fig. 5—Removing or Installing Caliper Fig. 7—Removing or Installing Inboard Shoe or fluid is evident, it will be necessary to disassemble until it is bottomed. Watch for possible reservoir caliper assembly and install a new seal, boot, (and pis­ overflow.

  • Page 185: Removing Caliper From Vehicle

    ♦ SERVICE—BRAKES 5-25 tern as described in “Bleeding the Brake System” OUTBOARD CALIPER MACHINED "WAYS" paragraph. It may have been necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. (8) Install wheel and tire assemblies and wheel covers.
  • Page 186 5-26 BRAKES—SERVICE are to be removed, disconnect front caliper pistons brake line at frame bracket after removing flexible first piston. Plug brake tube to remove piston from opposite caliper.) 'AUTION: Under no condition should air pressure be used to remove piston from bore. Personal injury could result from such practice.
  • Page 187 ♦ SERVICE—BRAKES 5-27 sure linings are installed in their original position. (1) Slide new outboard shoe and lining assembly in recess of caliper. CAUTION: No free play between brake shoe flanges and caliper fingers (Fig. 9) should exist (which might cause brake shoe rattle).
  • Page 188 5-28 BRAKES—SERVICE (1) Scoring, rust, impregnation of lining material and worn ridges: If a vehicle has not been driven for a period of time the disc will rust in the area not cov­ ered by the lining and cause noise and chatter. Ex­ cessive wear and scoring of the disc can cause temporary improper lining contact if ridges are not removed before installation of new lining (pads).
  • Page 189 ♦ ------------------------------------------------------------------------------------------------------------------------------- ---— SERVICE—BRAKES 5-29 from edge of disc (Fig. 2). Thickness measurements Example: should not vary more than .001 inch (.125mm). Minimum Allowable Thickness .940 (23.8mm) (4) Light scoring and/or wear is acceptable. If Allow for Wear .030 (,762mm) eavy scoring or warping is evident the disc should Do Not Reface Beyond .970 (24.6mm)
  • Page 190 5-30 BRAKES—SERVICE surfaces at the trailing end. A caliper support key is SHOE AND SHOE AND CALIPER BLEEDER SCREW installed between the leading edge of the caliper and he adapter with a support spring inserted between the key and the caliper. A key retaining screw keeps the key from sliding out of the anchor bracket.

  • Page 191: Routine Maintenance

    SERVICE—BRAKES 5-31 ♦--------------------------------------------------------------------------------------------------------- roughness will not clear up and the disc must be re­ ROUTINE MAINTENANCE placed. Check Brake Lines, Hoses and Linings Raise all four wheels. Remove front wheel and tire DISC BRAKE SERVICE PRECAUTIONS assemblies and inspect the braking disc, linings and (1) Grease or any other foreign material must be caliper.
  • Page 192 BRAKES—SERVICE 5-32 to the caliper; thus, it should not be necessary t< (2) Raise and support vehicle on hoist or jack- stands, and remove wheel and tire assemblies. bleed the brakes after the new shoes and linings ar< (3) Place a large C-Clamp on the caliper as shown installed.
  • Page 193 SERVICE—BRAKES 5-33 CLEANING AND INSPECTION CALIPER (1) Examine linings for wear, shoes should be re­ placed if the lining (pads) are worn to within .030 inch of the rivet heads. (2) Examine inside of caliper for piston leaks (evi­ dent by brake fluid in and around boot area and in­ board lining), and for any rupture of piston seal boot.
  • Page 194 5-34 BRAKES—SERVICE ♦ move vehicle until a firm pedal has been obtained CALIPER and master cylinder fluid level is correct. .^LIPER OVERHAUL Caliper-Piston Removal (1) Raise vehicle and support on hoist or jack- stands. Remove wheel and tire assembly. (2) Clean brake hose and tubing connections at caliper and brake line.
  • Page 195 ♦ ------------------------------- SERVICE—BRAKES 5-35 properly seated. Be sure seal is not twisted or rolled (Fig. 12). (3) Coat new piston boot with brake fluid. Install in caliper by working into outer groove, using fingers only. (Boot will seem larger than diameter of groove, but will snap into place when properly positioned in groove (Fig, 13).

  • Page 196: Removing Braking Disc And Hub

    5-36 BRAKES—SERVICE brake output when disc section is uneven. Dishing seal bushing wear due to necessity of caliper to fol­ distortion can be caused by extreme heat and ab low disc wobble. of the brakes. Thickness variation in a disc can also result in pedal pulsation, chatter and surge due to variation in SERVICE PROCEDURES Braking Disc).
  • Page 197 SERVICE—BRAKES 5-37 ♦ Fig. 3—Removing Caliper Lock and Spring Fig. 5—Removing or Installing Outer Lock Nut (2) Thoroughly clean bearings and interior of hub, suitable remover. removing all old grease. To clean bearings, soak them (4) Replace bearing cups with a suitable installer. in cleaning solvent.
  • Page 198 ------------------------------------------------------------------------------------------- « 5-38 BRAKES—SERVICE (10) Install wheel and tire assembly. Tighten nuts (9) Carefully position caliper onto adapter. Position 'pter lock and spring between caliper and adapter to specified torque (See Group 22). (11) Lubricate at all fittings. Remove jack stands, * tap into position (Fig.

  • Page 199: Service Brakes (150 Models)

    ♦ SERVICE—BRAKES 5-39 SERVICE BRAKES (D150, W150, ADI50/ AWT50, PD150/ PW150) INDEX Page Page Service Procedures ........... Shoe Installation Drum Refacing Recommendations ..... Rear Brake Shoes (D150, AD150, AW150, Drum Installation PD150, PW150, W150) ........Rear Brake Drums (W150, D150, AD150, Shoe Removal AW150, PD150, PW150, W150)......
  • Page 200 ------------------------------------------------------------------------- * 5-40 BRAKES—SERVICE TAB OF ANTI­ ameter with an accurate gauge. There should be no SECONDARY SHOE RATTLE SPRING variation in the drum diameter greater than .005 '‘ND LINING (BEHIND SHOE WEB) inch (.127mm). Drum runout should not exceed .007 inch (.178mm) out of round.
  • Page 201 SERVICE—BRAKES ♦ spring through guide and into web. Install other end SHOE ANCHOR PLATE over anchor, using Tool C-3785. (Be sure cable guide RETURN SPRING remains flat against shoe web and that secondary spring overlaps primary). (Fig. 1). Using pliers, squeeze ends of spring loops (around anchor) until TAB OF^.
  • Page 202 BRAKES—SERVICE 5-42...
  • Page 203 SERVICE—BRAKES 5-43 SERVICE PROCEDURES lever pivot pin. Unhook adjuster lever from adjuster BRAKE DRUM REMOVAL cable assembly. Rear (2) Under brake spring pliers (Fig. 6) unhook up­ (1) Raise vehicle on hoist or jacks and install jack per shoe-to-shoe spring.. Unhook and remove shoe stands for safety.
  • Page 204 5-44 BRAKES—SERVICE .nch (.127mm). Drum runout should not exceed .007 *ch (.178mm) out of round. If the drum runout or di- r variation exceed these values the drum ;ho-id be refaced. For best results in eliminating the rregularities that cause brake roughness and surge he amount of material removed during a single cut hould be limited to .005 inch (.127mm).

  • Page 205: Brake Drum Installation

    --------------- SUPPORT —BRAKES plates (3) Connect parking brake cable to parking brake (2) Install bearing and inner nut. lever. (3) While rotating wheel and tire assembly, tighter (4) Install and hook hold down springs (Fig. 7). inner (adjusting) nut until a slight bind is evident Back off adjusting nut 1/6 turn so that wheel will ro Using brake spring pliers (Tool C-312) replace up­...

  • Page 206: Wheel Cylinders

    5-46 BRAKES—WHEEL CYLINDERS WHEEL CYLINDERS INDEX Page Page Assembly ..............Installation..............Disassembly .............. Removal ......-........Cylinder walls that have light scratches, or show Removal With all brake drums removed inspect wheel cylin­ signs of corrosion, can usually be cleaned with crocus der boots (Fig.

  • Page 207: Servicing Brake Pedals

    WHEEL CYLINDERS—BRAKES 5-47 ♦-------------—-------------------------------------------------------- Install attaching bolts and tighten securely. Assembly (2) Apply sealing putty around wheel cylinder to Before assembling pistons and new cups in wheel prevent any water or dirt from entering brake as­ cylinder, dip them in brake fluid. If boots are deterio rated, cracked or do not fit tightly on brake shoe sembly.
  • Page 208 5-48 BRAKES—MASTER CYLINDER ♦ MASTER CYLINDER (ALUMINUM) INDEX Page Page Master Cylinder Fluid Level ........bleeding Master Cylinder ........Master Cylinder Removal....Cleaning and Inspection ......... Disassembling Master Cylinder......Reassembling Master Cylinder........ Testing Master Cylinder..........General Information ..........nstalling Master Cylinder........GENERAL INFORMATION complete master cylinder replacement.

  • Page 209: Master Cylinder Removal

    5.49 ------------ MASTER CYLINDER—BRAKES ♦-------------------------------------------------------------------------------------------------------------- -- the warning switch/Hold-Off valve and the front sary, before removing the reservoir caps, wipe caps brakes. This system is referred to as primary. The and reservoir clean to prevent dirt and other foreign master cylinder used on a vehicle not equipped with matter from dropping into the reservoir.
  • Page 210 >0 BRAKES-MASTER CYLINDER MASTER CYLINDER HOUSING PR292A Fig. 6—Removing or Installing Primary Piston Fig. 4—Removing or Installing Retainer Pin 4) Using a pair of needle nose pliers remove sec- roded, replace them with new ones. The piston cups iary piston retainer pin from inside master cylin- and seals should be replaced when reconditioning a housing (Fig.

  • Page 211: Bleeding Master Cylinder

    ♦ MASTER CYLINDER—BRAKES 5-51 secondary piston. Push piston assemblies into bore up INSTALLING MASTER CYLINDER to primary piston cup. Carefully work cup into bore Brake Equipped Power then push piston in up to the secondary seal. Care­ (1) Position master cylinder over studs of power fully work lip of primary cup into bore, then push in brake unit, aligning power brake push rod with mas­...

  • Page 212: Master Cylinder

    ------------------------------------------------------------------------ 5-52 BRAKES—MASTER CYLINDER -♦ only occur in the secondary chmber and so to deter­ voir caps, wipe caps and reservoir clean to prevent dirt and other foreign matter from dropping into the mine if the primary vent port is open, it will be cessary to pump up the brakes rapidly and, then, reservoir.
  • Page 213 MASTER CYLINDER—BRAKES 5-53 roded, replace them with new ones. All caps and seals ,CLAMP should be replaced when conditioning a master cylin­ der. When overhauling a master cylinder, use all parts furnished in repair kit. Discard all used rubber parts. ASSEMBLY Before assembling the master cylinder (Fig.
  • Page 214 5-54 BRAKES—HYDRAULIC SYSTEM CONTROL VALVES NU 828E Fig. 6-Tandem Master Cylinder (Disassembled) Connect push rod to brake pedal linkage. and observe for a geyser of fluid squirting up in res­ (3) Connect front and rear brake tubes and tighten ervoirs. This may only occur in front chamber and securely.
  • Page 215 HYDRAULIC SYSTEM CONTROL VALVES—BRAKES 5-55 PROPORTIONING WARNING SWITCH HOLD-OFF FROM MASTER FROM MASTER CYLINDER CYLINDER PRIMARY SECONDARY OUTLET OUTLET TO FRONT BRAKE OUTLET TO REAR BRAKES VALVE STEM TO FRONT BRAKE PK397B I— Assembly Fig. Combination Warning Switch/Hold Off/Proportioning (Sectional) Typical Cast Iron and braking response is directly proportional to pedal Brake Warning Switch Operation effort.
  • Page 216 5-56 BRAKES—HYDRAULIC SYSTEM CONTROL VALVES ♦ WARNING BRAKE Fig. 2—Combination Warning Switch/Hold Off Assembly—Typical Brass piston and automatically turn of! the warning light. brake warning switch piston and opens a bypass in THE VALVE SHOULD NOT BE DISASSEMBLED TO the proportioning unit allowing full rear brake hy- RESET THE PISTON.

  • Page 217: Proportioning Valve

    HYDRAULIC SYSTEM CONTROL VALVES—BRAKES 5-57 ♦ disconnected wire at the switch. If the bulb is not burned out and the wire continuity is proven, replace the valve and bleed the system. After repairing and bleeding the brake system (see “Bleeding Brake System” in service adjustments), ap­ plying the brakes with moderate force will hydrauli­...

  • Page 218: Specifications

    Inside Diameter..7.775' (197mm) 8.86"*225mm) 8.86' (225mm) 8.30"'223mm) Type........Vertilated Ventilated Ventilated Ventilated Thickness....... 1.25"(31.75mm) 1.25"(31.75mm) l.:9''(30mm) ,.19"(30mmj Caliper—Make ....Chrysler Chrysler Chrysler Bendix Type........Sliding Sliding Sliding Sliding Piston Diameter..3.10"(78.7mm.' 3.1D'(78.7rm) "( £. 3.38"(85.8mm) lining—Make ..... CP01816...

  • Page 219: Tightening Reference

    Brake Line Tube Nuts, 3/8 or 7/16 ........(9.8-18.4) 80-150 1/2 or 9/16 ........125-175 (15.3-21.5) (162) Bottom attaching bolts ............DISC BRAKE (CHRYSLER) Adaptor Mounting Bolts D150-D250-AD150-PD150....(149) W150, AW 150, PW150, W250 ..........(203) D250 H.D., D350, D450 ............(216) (24.5) Retainer and Anti-Rattle Spring ...........
  • Page 220 Passenger Car -rrr~y:* • Service Chassis, Manual Body, Electrical Omni LeBaron Horizon Rampage Aries Reliant Dodge 400...

  • Page 221: Group Index

    GROUP INDEX — Introduction 0 Lubrication and Maintenance Suspension jg— Foreword Brakes This Service Manual has been prepared with the latest servicing information available at the time of publication. It is subdivided into various group cate­ III- 6 Clutch gories and each section contains diagnosis, disassem­ bly, repair, and installation procedures along with complete specifications and tightening references.
  • Page 222 —BRAKES-----------------------------------------------5-1 BRAKES CONTENTS Page Page POWER BRAKES..........BRAKE DISC (ROTOR)......... SERVICE ADJUSTMENTS......DISC BRAKES..........SERVICE DIAGNOSIS........f. DRUM BRAKES..........SPECIFICATIONS.......... I HYDRAULIC SYSTEM CONTROL VALVES .. fc MASTER CYLINDER........TIGHTENING REFERENCE......WHEEL CYLINDERS........j PARKING BRAKES........SERVICE ADJUSTMENTS INDEX Page Page ....

  • Page 223: Master Cylinder Fluid Level

    BRAKES MASTER CYLINDER FLUID LEVEL the left front and right rear brakes on one hydraulic system, and the right front and left rear on the other. Check master cylinder reservoir fluid level twice The master cylinder is anodized, lightweight alumi- annually.

  • Page 224: Wheel Stud Tightening

    BRAKES Inspection TEST FOR FLUID CONTAMINATION Inspection of brake hoses should be performed Indications of fluid contamination are swollen or whenever the brake system is serviced and every deteriorated rubber parts. 7,500 miles or 12 months, whichever comes first Swollen rubber parts indicate the presence of pe­ (every engine oil change).
  • Page 225 BRAKES...
  • Page 227 BRAKES • • • • • • CO CO CO CO CO CO § O' R o> £ *£ <5 »...
  • Page 228 BRAKES Place 4.76 mm (3/16 in.) plug of gauge down in STOP LAMP SWITCH ADJUSTMENT P, D, C, V end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in The stop lamp switch incorporates a new self ad­ justing feature.
  • Page 229 BRAKES BASIC DIAGNOSIS GUIDE CHART 1 CHART 3 CHART 3 CHART 4 CHART 5 MISC. COND. ACTUATION POWER NOISE WHEEL BRAKES SYMPTOM BRAKE WARNING LIGHT "ON" EXCESSIVE PEDAL TRAVEL PEDAL GOES TO FLOOR STOP LIGHT "ON" WITHOUT BRAKES ALL BRAKES DRAG REAR BRAKES DRAG GRABBY BRAKES SPONGY BRAKE PEDAL...
  • Page 230 ------------- BRAKES------------------ BRAKE CHART 1 DIAGNOSIS SHEET 2 OF 5 RB835A...
  • Page 231 5-10 BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS CHECK AND REPAIR RELEASE PARKING BRAKE ELECTRICAL CIRCUIT LIGHT GOES OFF AS REQUIRED CHECK WIRE CONNECTED CHECK; MASTER CYLINDER TO WARNING SWITCH IN FLUID LEVEL ENGINE COMPARTMENT...
  • Page 232 BRAKES 5-11 BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS SHEET 4 OF 5 RB835A...
  • Page 233 5-12 BRAKES BRAKE CHART 4 BRAKE NOISE DIAGNOSIS DETERMINE NOISE LOCATION FRONT OR REAR "*MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED OR REDUCED BY ROTATING DRUM (REAR) TWO STUDS ON AXLE FLANGE SHEET 5 OF 5 RB835A...

  • Page 234: General Information

    -DRUM BRAKES- -5-13 DRUM BRAKES INDEX Page Page Brake Drum and Shoe Removal......Drum Refacing............Brake Drum and Shoe Installation......General Information ..........Cleaning and Inspection ......... Service Diagnosis ............ Service Procedures ..........GENERAL INFORMATION Rear wheel brakes (Figs. 1 and 2) are two-shoe, in­ chor plate affixed to the support.
  • Page 235 5-14 DRUM BRAKES RETURN FRONT CYLINDER BOOT SPRING BRAKE (PRESS FIT) CYLINDER: parking BRAKE LEVER HOLD DOWN .''SPRING PIN , TRAILING SHOE AND LINING SUPPORT PARKING LEADING SHOE BRAKE CABLE LINING ANCHOR PLATE SHOE TO ANCHOR SPRING PR560B Fig. 2. Left Rear Wheel Brake and disengage return spring end from support (Fig.
  • Page 236 DRUM BRAKES 5-15 FRONT Lubricate shoe tab contact areas (six places in Fig. Drum Refacing Measure drum runout and diameter. If not to 13) on support plate and web ends of brake shoes that specification, reface drum. (Runout should not exceed contact anchor plate, using MOPAR Multi-Purpose .1524 mm or .006 in.).
  • Page 237 DRUM BRAKES 5-16 FRONT PR568A Fig. 10. Removing Leading Brake Shoe Fig. 13. Shoe Contact Areas on Support Plate ADJUSTER NUT SCREW THREADS PU205A Fig. 11. Adjuster Screw Assembly / PR572 Fig. 14. Installing Grease Seal...
  • Page 238 DRUM BRAKES 5-17 stall trailing shoe and lever assembly at same time as Installation Install leading shoe return spring in position on engaging spring end in support. Position end of shoe under anchor plate (Fig. 16). shoe. Install leading shoe at same time as engaging Spread shoes and install adjuster screw assembly.
  • Page 239 DRUM BRAKES 5-18 FRONT Fig. 19. Installing Shoe to Anchor Springs outer bearing, washer and nut. Tighten adjusting nut to 27-34 N’rn (240-300 in .lbs.) Compress parking brake cable housing spring while rotating brake drum. slightly to expose cable, then slide into position in Back off adjusting nut with wrench to completely parking brake lever.
  • Page 240 CONTROL VALVES 5-19 HYDRAULIC SYSTEM CONTROL VALVES INDEX Page Page Brake Warning Switch Genera! Information ..........Checking Brake Warning Switch Unit..... Brake Warning Switch Operation......Height Sensing Proportioning Valve Height Sensing Proportioning Unit Operation — Testing Height Sensing Proportioning Valve .. Service Procedures...........

  • Page 241: Control Valves

    5-20 CONTROL VALVES Fig. 2. Rear Brake Height Sensing Proportioning Valve Z-28 interrupted, check the service brake warning switch gauge and check the reading on the outlet gauge. The inlet pressure should be 1000 psi and the outlet operation with a test lamp between the switch ter­ minal.

  • Page 242: Disc Brakes

    5-21 DISC BRAKES until all free play has been removed from the spring. Installation and Adjustment After installing a new height sensing proportioning (Do not stretch spring). Hold the adjusting bracket in valve, bleed both rear brakes. position and release the valve lever. Tighten nut “B” to temporarily hold the adjusting bracket in this posi­...
  • Page 243 5*22 DISC BRAKES The adapter for M, Z, Z-28, is mounted to the steer­ ing knuckle by two special nylock bolts and coned washer assemblies. The adapter for the P, D, C, V models is mounted to the steering knuckle by* two special nylock, flange head bolts having faces that are serrated.
  • Page 244 DISC BRAKES 5-23 Handling the braking disc and caliper should be done in such a way as to avoid deformation of the disc and scratching or nicking the brake linings (pads). If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately.
  • Page 245 DISC BRAKES 5-24 Fig. 9. Removing or Installing Braking Disc Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc (Fig. 7). Slide braking disc off drive axle flange and studs Support caliper firmly so as not to damage flexible (Fig.
  • Page 246 DISC BRAKES 5-25 Loosen, do not remove caliper guide pins until Removal P, D, Raise vehicle on jackstands or centered on a hoist. caliper is free. Remove guide pins only if bushings or Remove front wheel and tire assemblies. sleeves are to be replaced. Remove hold-down spring from caliper assembly Lift caliper out and away from braking disc (Fig.

  • Page 247: Disassembling Caliper

    DISC BRAKES 5-26 Lift the outboard shoe and lining from the adapter Cleaning and Inspection Check for piston seal leaks (brake fluid in and (Fig. 14). around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored).
  • Page 248 5-27 DISC BRAKES Fig. 15. Disc Brake Caliper—M,Z, Z-28 (Disassembled View)

  • Page 249: Assembling Caliper

    © ■ 5-28 DISC BRAKES Bores that have deep scratches or scoring should Black stains on the steel piston are caused by the be honed, using Tool C-4095, providing the diameter piston seal and will do no harm, carlines M, Z, Z-28. of the bore is not increased more than .0254 mm (.001 When using Hone C-4095, coat the stones and bore inch).
  • Page 250 DISC BRAKES 5-29 C, V, and Tool C-4682 for carlines M, Z, Z-28 with Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one C-4171 handle, drive boot into counterbore. (Fig. 23). area in groove and gently worked around the groove, using fingers until properly seated.

  • Page 251: Bleeding Disc Brakes

    DISC BRAKES 5-30 Be sure flanges extend over caliper casting evenly on both sides. Before installing caliper assembly on vehicle, in­ spect braking disc. Conditions as described in “Checking Braking Disc for Runout and Thickness” paragraph. Install brake hose to caliper using new seal wash­ ers.
  • Page 252 5-31 BRAKE DISC (ROTOR) BRAKE DISC (ROTOR) INDEX Page Page Refacing Braking Disc..........Checking Braking Disc for Runout......Removing Braking Disc ........... General Information ..........Installing Braking Disc ........... Resurfacing Braking Disc........Service Procedures ..........GENERAL INFORMATION Any servicing of the braking disc requires extreme Excessive wear and scoring of the disc can cause care to maintain the braking disc within service tol­...
  • Page 253 5-32 BRAKE DISC (ROTOR) SERVICE PROCEDURES on hub with chalk marks 180 degrees apart (Fig. 4). CHECKING BRAKING DISC FOR RUNOUT Finally, recheck runout of disc to see if runout is now AND THICKNESS within specifications .127 mm (.005"). If runout is in excess of specifications, install a new “On vehicle, braking disc (rotor) runout”...
  • Page 254 BRAKE DISC (ROTOR) 5-33 possible from each side of disc. Remove equal amounts REMOVING BRAKING DISC from each side of disc. Do not reduce thickness below minimum thickness (10.95 mm (.431 in.) M, Z, Z-28 (1) Raise vehicle on hoist or jackstands. Remove models, and 22.4 mm (.882 in.) for P, D, C, V models) wheel and tire assembly.
  • Page 255 5-34 BRAKE DISC (ROTOR) REFINISHING (REFACING) BRAKING DISC Resurfacing Braking Disc This operation can be used when the disc surface is rusty or has lining deposits. A sanding disc attachment will remove surface contamination without removing much material. It will generally follow variations in thickness which are in the disc.

  • Page 256: Wheel Cylinders

    -WHEEL CYUNDERS- -5-35 WHEEL CYLINDERS INDEX Page Page Assembling Wheel Cylinders ... Installing Wheel Cylinders ........Removing Brake Supports........Disassembling Wheel Cylinders General Information ....Removing Wheel Cylinders........Installing Brake Supports..Service Procedures........... GENERAL INFORMATION The piston boots (Fig. 1) are of the press-on type and prevent moisture from entering the wheel cylin­...
  • Page 257 5-36- -WHEEL CYLINDERS- Slide piston into cylinder bore and press to re­ move opposite piston, cups, and spring with cup ex­ panders from cylinder bore. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; clean thoroughly and blow dry with compressed air.
  • Page 258 PARKING BRAKES 5-37 |^g) REMOVING BRAKE SUPPORT ASSEMBLY INSTALLING BRAKE SUPPORT ASSEMBLY Back off parking brake adjusting nut to provide Insert parking brake cable and housing into support plate. slack in cable. With wheel and brake drum removed disconnect Install support plate and spindle on to rear suspen­ tube from wheel cylinder.
  • Page 262 5-41 PARKING BRAKES (Fig. 4), compress retainers on end of cable and re­ P, D, C, Loosen cable adjusting nut under car and disengage move from chassis mount. front cable from connectors (Fig. 2). Disconnect cable from brake shoe lever. Using an aircraft type hose clamp and screwdriver, Lift floor mat for access to-floor pan.

  • Page 263: Cleaning And Inspection

    5-42 MASTER CYLINDER MASTER CYLINDER INDEX Page Bleeding Master Cylinder........Master Cylinder Fluid Level ........Cleaning and Inspection ......... Master Cylinder Removal ........Disassembling Master Cylinder......Reassembling Master Cylinder ......General Information ..........Testing Master Cylinder........... Installing Master Cylinder........Service Procedures..........GENERAL INFORMATION The tandem aluminum master cylinder (Figs.

  • Page 264: Master Cylinder Removal

    5-43 MASTER CYLINDER SERVICE PROCEDURES from under instrument panel. Pull stop lamp switch MASTER CYLINDER REMOVAL out of way to prevent switch damage. Power Brake Equipped Pull brake pedal backward sharply to disengage Disconnect primary and secondary brake tubes push rod from master cylinder piston. This will de­ from master cylinder.

  • Page 265: Cleaning And Inspection

    5-44 MASTER CYLINDER PISTON SECONDARY PISTON ASSEMBLY Fig. 8. Removing Secondary Piston Fig. 6. Removing Snap Ring Install check flow washer. move secondary piston. If it sticks in bore of cylin­ Carefully place primary cup, with lip facing away der, use air pressure to force piston out of cylinder. from piston, on piston.

  • Page 266: Bleeding Master Cylinder

    MASTER CYLINDER unit, align push rod with master cylinder piston. Install attaching nuts and tighten to specification. Connect brake tubes and tighten to specification. Bleed brakes. Manual Brake Equipped Install the push rod boot on the push rod. Install a new push rod grommet onto push rod. Moisten push rod grommet and press push rod firmly into primary piston socket until it seats.
  • Page 267 M, Z, Z-28 models equipped with the 2.2L engine routings. Vehicles equipped with the Chrysler 2.2L use a power brake unit, and vacuum hose connections engine use a charcoal filter in the hose between the as shown in (Fig.
  • Page 268 POWER BRAKES 5-47 RB107A Fig. 3. Power Brake Unit/Vacuum Hose Connections Fig. 5. Power Brake Mounting M,Z, Z-28 2.2L Engines SERVICE PROCEDURES center tang to pass over end of brake pedal pin and REMOVING POWER BRAKE UNIT pull retainer clip from pin. Discard retainer clip. Remove nuts attaching master cylinder to power Remove four power brake attaching nuts.

  • Page 269: Hydraulic System

    5-48---------------------------------- SPECIFICATIONS----------- --------------:-------------------- SPECIFICATIONS DRUM BRAKE _______________________________MetricU. S. Customary Type .................. Leading Trailing Single Anchor 7.87 in. Diameter—Standard ............... 200mm 1.18 in. Width—Standard ..............30mm Lining 8 in. x 3/16 in. Leading—Length & Thickness—Standard....203.2mm x 4.76mm 8 in. x 3/16 in. Trailing—Length &...
  • Page 270 TIGHTENING REFERENCE M,Z____________________Z-28_________________ P, D, C, V Primary, Scondary (Displacement) ....Split 50/50 Split 50/50 Split 50/50 Outlet Port Threads....3/8 x 24 — 3/8 x 24 Fitting Type ........ 45° Inverted Flare — 45° Inverted Flare PEDAL RATIO Manual...........
  • Page 271 RB836A PF558 C-4007A...
  • Page 272 Service / Truck 1982 Manual...
  • Page 273 CORPORATION Body Heaters and Air-Conditioning Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured. Emissions Control Systems Litho in U.S.A.
  • Page 274 GROUP PARKING BRAKES CONTENTS Page Page REAR WHEEL EXPANDING TYPE..... TIGHTENING REFERENCE......SPECIFICATIONS ........REAR WHEEL INTERNAL EXPANDING TYPE INDEX Page Page Removal ..............General Information ..........Service Procedures ..........Rear Cable.............. Adjustment ............Installation.............. ■ Front Cable ............... Removal ..............
  • Page 275 PARKING BRAKES ♦ NOT. ASSEMBLY -BODY (REFERENCE) <$> TORQUE 140 IN. LBS. 15.8 N»m 40.6 N*m 30 FT. LBS. 17 IN. LBS. 1.9 N«m $> 14.1 N.m 125 IN. LBS. 95 IN. LBS. 10.7 N«m <F> 47.4 N«m 35 FT. LBS. FRONT CABLE ASSEMBLY RIGHT REAR CABLE...
  • Page 276 PARKING BRAKES...
  • Page 277 ------------------------------------- ----- - -------- 4 PARKING BRAKES---------------------------------- (if) Remove cable housing anchor clip at parking INTERMEDIATE CABLE brake lever. ADI, AW1, PD1, PW1, D1, W1 (4) Remove anchor clip from lever. (5) Remove housing grommet from floor pan. Removal (1) Remove adjusting nut at adjusting link. Installation (2) Disengage rear end of cable from ratio lever (1) Insert cable and housing through floor pan and...
  • Page 278 HYDRAULIC SYSTEM CONTROL VALVES . SYSTEM....... bleeding brake MASTER CYLINDER INTERNAL LEAK DUO-SERVO..brake adjustment BRAKE HOSE AND TUBING....... CHECK ..........DISC BRAKE—CHRYSLER (D150, D250, MASTER CYLINDER D350, ADI50, PD150)......ALUMINUM ..........DISC BRAKE—BENDIX(W350, & CAST IRON..........W250 EXTRA) .......... SERVICE BRAKES (150 Models)....
  • Page 279 BRAKES----------------------- BASIC DIAGNOSIS GUIDE Chart 1 Chart 2 Chart 3 Chart 4 Chart 5 Misc. Cond. Actuation Power Noise Wheel Brakes Symptom Brake Warning Light "ON” Brake Chatter (Rough) Surge During Braking Noise During Braking Pull to Right or Left Premature Rear Lockup Rear Brakes Drag Brakes Drag—ALL...
  • Page 280 BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS...
  • Page 281 BRAKES---------------------------------------------------------------------------------------------------------- BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS PH 634E...
  • Page 282 BRAKES ♦ BRAKE CHART 4 BRAKE NOISE DIAGNOSIS ••INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED 'WAYS" OF CALIPER AND ADAPTER. ***MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932324, OR EQUIVALENT. PU57 BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMINATED ROTATION DRUM (REAR) TWO OR REDUCED BY PH 632E...
  • Page 283 ♦ BRAKES—HYDRAULIC SERVICE PROCEDURES into a small clear glass bottle. Separation of the fluid HYDRAULIC BRAKE SYSTEM into distinct layers will indicate mineral oil content. Servicing the hydraulic system is chiefly a matter of Be safe and discard old brake fluid that has been bled adjustments, replacement of worn or damaged parts from the system.
  • Page 284 HYDRAULIC—BRAKES ♦ ——------------------------------------------------------------------------- ------- --------- — falling into the master cylinder reservoir when the Pedal Bleed: This method of bleeding is not af­ -r is removed. fected by the hold-off valve, as fluid pressures are in Check brake master cylinder to be sure boot is excess of 165 psi (1137.6 kPa).
  • Page 285 ------------------------------------------------------------------------ « BRAKES—HYDRAULIC----------------------------- felt when road xotated. fn a trapped air condition, the brake warning light wheel is (5) For (Fig. 2), insert ad­ application type adjuster will go off when brake pedal is released. If warning light does after you release justing Tool C-3784, into star wheel of adjusting not go off brake pedal, the master cylinder is bad or hydraulic...
  • Page 286 HYDRAULIC—BRAKES automatic adjusters do not function properly, the re­ all brake service operations. stive drum must be removed for adjuster serv- Always use factory recommended hose to insure quality, correct length and superior fatigue life. Care should be taken to make sure that the tube and hose WHEEL STUD TIGHTENING mating surfaces are clean and free from nicks and The tightening sequence and torquing of the wheel...

  • Page 287: Disassembling Caliper

    (6) Tighten handles of flaring tool and lock tubing seat. in place. (11) Clean seat and tube of any lubricant before (7) Place proper sized plug of gauge “A” down in connecting to hydraulic system. DISC BRAKE-CHRYSLER (D150/ D250, D350, ADI 50, PD150) INDEX Page Page Assembling Caliper...........
  • Page 288 DISC (SLIDING CALIPER)—BRAKES 5-11 a hydraulic seal between the piston and the cylinder CALIPER -11 (Fig. 3). The adaptor is mounted to the steering jckle by two special nylock bolts (Figs. 1 and 3). A moulded rubber dust boot installed in a groove RETENTION in the cylinder bore and piston keeps contamination FLANGE...
  • Page 289 5-12 BRAKES—DISC (SLIDING CALIPER) PISTON BRAKE FLUID WHEEL STUD SPINDLE BRAKING DISC NU4E Fig. 3—Disc Brake Assembly (Sectional)

  • Page 290: Service Procedures

    DISC (SLIDING CALIPER)—BRAKES 5*13 ♦ Fig. 5-Piston Seal Function For Automatic Adjustment inspected at this time and replaced if necessary). caliper assembly must be removed in order to inspect (Refer to “Brake Shoe Re­ the inner wheel bearings. moval” paragraph). Do not get oil or grease on the braking disc or lin­...

  • Page 291: Brake Shoe Installation

    5-14 BRAKES—DISC (SLIDING CALIPER) Fig. 6—Removing or Installing Caliper mating surfaces of the abutments on the caliper and adaptor. If corroded or rusty, clean surfaces with wire Fig. 8—Removing or Installing Shoe brush. Inspect braking surfaces of disc. shoe after above modification, if necessary, by snap­ BRAKE SHOE INSTALLATION ping shoe into place with fingers or with light “C”...
  • Page 292 DISC (SLIDING CALIPER)—BRAKES 5-15 ♦ (7) Check and refill master cylinder reservoirs (if essary) with brake fluid as required. It DOT 3 suould not be necessary to bleed the system after shoe and lining removal and installation. However, if a firm pedal cannot be obtained bleed the brake sys­ tem as described in “Bleeding the Brake System”...
  • Page 293 5-16 B.RAKES—DISC (SLIDING CALIPER)— ♦ protector jaws. Caution: Excessive vise pressure will cause bore distortion and binding of piston. aliper (6) Remove dust boot using suitable tool. (7) Using a small, pointed, wooden or plastic stick, work piston seal out of its groove in piston bore (Fig. 13).
  • Page 294 —DISC (SLIDING CALIPER)—BRAKES 5-17 ♦ (3) Slowly slide caliper assembly into position adaptor and over disc. Align caliper on machined ways of adaptor. Be careful not to pull the dust boot from its groove as the piston and boot slide over the inboard shoe.
  • Page 295 ♦ BRAKES—DISC (ROTOR) 5-18 BRAKING DISC (D150/ D250, D350, ADI 50, PD150) INDEX Page Page Refacing Braking Disc ..........Checking Braking Disc for Runout......Removing Braking Disc ........... General Information ..........Resurfacing Braking Disc ........Inspection Diagnosis..........Installing Braking Disc (and Hub)......GENERAL INFORMATION Any servicing of the brake disc requires extreme the lining and cause noise and chatter.
  • Page 296 -----------------—DISC (ROTOR)—BRAKES 5-19 ------------------------------------------------------------------------- stands. Remove wheel cover and wheel and tire as­ from edge of disc. If thickness measurements exceed ecifications, disc should be removed and resurfaced sembly. a new disc and hub assembly installed (Fig. 1). (2) Remove caliper assembly as described under (4) Light scoring and/or wear is acceptable.
  • Page 297 (.381-.457) 1.170/1.190 .001 D250 Extra, .005 15-80 (29.71/30.22mm) D350 (.025mm) (.127mm) (.381-.457) DISC BRAKE-CHRYSLER (W150, W250, AW150, FW150) Page Page Assembling Caliper........... Hold-Off Valves............Brake Roughness............Installing Caliper ............Brake Shoe Installation ........... Removing Caliper from Vehicle....... Brake Shoe Removal..........
  • Page 298 SERVICE—BRAKES 5-21 The cast iron braking disc has cooling fins or lou- wiping lip that prevents contamination in the bore *s that are cast integrally between the two area. achined braking surfaces (Fig. 2). As the brake pedal is depressed, hydraulic When the wheel is in motion, the rotation of the pressure is applied against the piston.

  • Page 300: Brake Shoe Removal

    SERVICE—BRAKES 5-23 ♦ stand unused for n^iodc time in areas of high hu­ midity or salt air may incur rust on the disc which could cause a temporary brake surge and roughness. Normally however, this condition should correct it­ self after a short period of usage. If rust is severe enough roughness will not clear up and the disc must be replaced.
  • Page 301 5-24 BRAKES—SERVICE ♦ Fig. 7—Removing or Installing Inboard Shoe Fig. 5—Removing or Installing Caliper until it is bottomed. Watch for possible reservoir or fluid is evident, it will be necessary to disassemble overflow. See step 9 of “Disc Brake Service Precau­ caliper assembly and install a new seal, boot, (and pis­...
  • Page 302 SERVICE—BRAKES 5-25 ♦ tem as described in “Bleeding the Brake System” paragraph. It may have been necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. (8) Install wheel and tire assemblies and wheel covers.
  • Page 303 5-26 BRAKES—SERVICE------------------------------ - ♦ frQnt caliper pistons are to be removed, disconnect flexible brake line at frame bracket after removing CALIPER first piston. Plug brake tube to remove piston from opposite caliper.) SPECIAL HONE CAUTION: Under no condition should air pressure be used to remove piston from bore.
  • Page 304 SERVICE—BRAKES 5-27 ♦ sure linings are installed in their original position. (1) Slide new outboard shoe and lining assembly in recess of caliper. CAUTION: No free play between brake shoe flanges and caliper fingers (Fig. 9) should exist (which might cause brake shoe rattle).
  • Page 305 5-28 BRAKES—SERVICE---------------------------- '“-(1) Scoring, rust, impregnation of lining material and worn ridges: If a vehicle has not been driven for a period of time the disc will rust in the area not cov­ ered by the lining and cause noise and chatter. Ex­ ALL MEASUREMENTS cessive wear and scoring of the disc can cause ONE INCH FROM EDGE...
  • Page 306 SERVICE—BRAKES 5-29 ♦——- - ---------------------------------------------------------------------------------------------- from edge of disc (Fig. 2). Thickness measurements Example: -’-ould not vary more than .001 inch (.125mm). Minimum Allowable Thickness .940 (23.8mm) ;) Light scoring and/or wear is acceptable. If Allow for Wear .030 (.762mm) heavy scoring or warping is evident the disc should Do Not Reface Beyond .970 (24.6mm)
  • Page 307 ------------------------------------------------------------------------ ♦ 5-30 BRAKES—SERVICE-------------------------------- surfaces at the trailing end. A caliper support key is SHOE AND SHOE AND CALIPER BLEEDER SCREW installed between the leading edge of the caliper and the adapter with a support spring inserted between the key and the caliper. A key retaining screw keeps the key from sliding out of the anchor bracket.

  • Page 308: Service Procedures

    ------------------------------- SERVICE—BRAKES 5-31 ♦ ----------------- - --------------------------------------------------------------------------------------------------------- roughness will not clear up and the disc must be re­ routine maintenance placed. heck Brake Lines, Hoses and Linings Raise all four wheels. Remove front wheel and tire DISC BRAKE SERVICE PRECAUTIONS assemblies and inspect the braking disc, linings and (1) Grease or any other foreign material must be caliper.
  • Page 309 5-32 BRAKES—SERVICE '♦ "C" Fig. 7—Removing Outboard Shoe from Caliper Fig. 5—Pushing Piston into Bore with Clamp (2) Raise and support vehicle on hoist or jack- to the caliper; thus, it should not be necessary to stands, and remove wheel and tire assemblies. bleed the brakes after the new shoes and linings are (3) Place a large C-Clamp on the caliper as shown installed.
  • Page 310 SERVICE—BRAKES 5-33 ♦——~----------------------------------------------------------------------------------------------------------- CLEANING AND INSPECTION v-^urtR (1) Examine linings for wear, shoes should be re­ placed if the lining (pads) are worn to within .030 inch of the rivet heads. (2) Examine inside of caliper for piston leaks (evi­ dent by brake fluid in and around boot area and in­...
  • Page 311 5-34 BRAKES—SERVICE------------------------------ - ----- 1 — -—■-------------------------------------------------------------------------------------------------------------------------------------- --- move vehicle until a firm pedal has been obtained CALIPER and master cylinder fluid level is correct. CALIPER OVERHAUL Caliper-Piston Removal (1) Raise vehicle and support on hoist jack- stands. Remove wheel and tire assembly. (2) Clean brake hose and tubing connections at caliper and brake line.
  • Page 312 ------------------------------- SERVICE—BRAKES 5-35 ♦ properly seated. Be sure seal is not twisted or rolled (Fig. 12). (3) Coat new piston boot with brake fluid. Install in caliper by working into outer groove, using fingers only. (Boot will seem larger than diameter of groove, but will snap into place when properly positioned in groove (Fig.

  • Page 313: Removing Braking Disc And Hub

    5-36 BRAKES—SERVICE-------------------------------------------------------------------------------------------------------------- ♦ seal bushing wear due to necessity of caliper to fol- brake output when disc section is uneven. Dishing or low disc wobble. distortion can be caused by extreme heat and abuse Thickness variation in a disc can also result in of the brakes, pedal pulsation, chatter and surge due to variation in SERVICE PROCEDURES...
  • Page 314 ♦ SERVICE—BRAKES 5-37 3-Removing Fig. Caliper Lock and Spring Fig. 5—Removing or Installing Outer Lock Nut Thoroughly clean bearings and interior of hub, suitable remover. removing all old grease. To clean bearings, soak them (4) Replace bearing cups with a suitable installer. in cleaning solvent.
  • Page 315 ------------ .--------- ---------------------------- 5-38 BRAKES—SERVICE-------------------------------- (9) Carefully position caliper onto adapter. Position (10) Install wheel and tire assembly. Tighten nuts adapter lock and spring between caliper and adapter to specified torque (See Group 22). (11) Lubricate at all fittings. Remove jack stands, and tap into position (Fig.
  • Page 316 SERVICE—BRAKES 5-39 ♦ SERVICE BRAKES (D150, W150, ADI 50/ AW150/ PD150, PW150) INDEX Page Page Service Procedures......Drum Removal ............Drum Refacing Recommendations Shoe Installation ..........Drum Installation......Shoe Removal............SERVICE PROCEDURES DRUM REMOVAL SHOE REMOVAL (1) With vehicle on a hoist, jack, or suitable stands, (1) Using Tool C-3785, remove brake shoe return springs (Fig.
  • Page 317 « ------------------------------------------------------------------------ * 5-40 BRAKES—SERVICE ameter with an accurate gauge. There should be no variation in the drum diameter greater than .005 inch (.127mm). Drum runout should not exceed .007 inch (.178mm) out of round. If the drum runout or di­ ameter variation exceed these values the drum should be refaced.

  • Page 318: General Information

    SERVICE—BRAKES 5-41 ♦ spring through guide and into web. Install other end over anchor, using Tool C-3785. (Be sure cable guide remains flat against shoe web and that secondary spring overlaps primary). (Fig. 1). Using pliers, squeeze ends of spring loops (around anchor) until parallel.

  • Page 320: Service Procedure

    SERVICE—BRAKES 5-43 SERVICE PROCEDURES lever pivot pin. Unhook adjuster lever from adjuster ^RAKE DRUM REMOVAL cable assembly. Rear (2) Under brake spring pliers (Fig. 6) unhook up­ Raise vehicle on hoist or jacks and install jack per shoe-to-shoe spring. Unhook and remove shoe stands for safety.

  • Page 321: Brake Shoe Installation Rear

    5-44 BRAKES—SERVICE---------------------------- itich (.127mm). Drum runout should not exceed .007 inch (.178mm) out of round. If the drum runout or di­ ameter variation exceed these values the drum should be refaced. For best results in eliminating the irregularities that cause brake roughness and surge the amount of material removed during a single cut should be limited to .005 inch (.127mm).
  • Page 322 SUPPORT PLATES—BRAKES 5-45 ♦ (3) Connect parking brake cable to parking brake (2) Install bearing and inner nut. ?ver. (3) While rotating wheel and tire assembly, tighten (4) Install and hook hold down springs (Fig. 7). inner (adjusting) nut until a slight bind is evident. Using brake spring pliers (Tool C-312) replace up­...

  • Page 323: Wheel Cylinders

    5-46 BRAKES—WHEEL CYLINDERS- ♦ WHEEL CYLINDERS INDEX Page Page Installation..............Assembly ..............Removal ....-..........Disassembly .............. Cylinder walls that have light scratches, or show Removal With all brake drums removed inspect wheel cylin­ signs of corrosion, can usually be cleaned with crocus der boots (Fig.
  • Page 324 WHEEL CYLINDERS—BRAKES 5-47 ♦—-------------------------------------------------------------------- Install attaching bolts and tighten securely. Assembly (2) Apply sealing putty around wheel cylinder to Before assembling pistons and new cups in wheel cylinder, dip them in brake fluid. If boots are deterio­ prevent any water or dirt from entering brake as­ rated, cracked or do not fit tightly on brake shoe sembly.
  • Page 325 5-48 BRAKES—MASTER CYLINDER » MASTER CYLINDER (ALUMiNUM) INDEX Page Page Bleeding Master Cylinder ..Master Cylinder Fluid Level ........Cleaning and Inspection ..Master Cylinder Removal...... Disassembling Master Cylinder Reassembling Master Cylinder......... General Information ....Testing Master Cylinder..........Installing Master Cylinder..GENERAL INFORMATION The new family of corporate aluminum master complete master cylinder replacement.

  • Page 326: Master Cylinder Removal

    MASTER CYLINDER—BRAKES 5-49 ♦-------------------------------------------------------------------------------------------------------------------------- sary, the warning switch/Hold-Off valve and the before removing the reservoir caps, wipe caps front brakes. This system is referred to as and reservoir clean to prevent dirt and other foreign primary. matter from dropping into the reservoir. If necessary master cylinder used on a vehicle not equipped with a power brake unit is serviced in the same manner as...
  • Page 327 5-50 BRAKES—MASTER CYLINDER ♦ MASTER CYLINDER HOUSING PR292A Fig. 6—Removing or Installing Primary Piston Fig. 4—Removing or Installing Retainer Pin (4) Using a pair of needle nose pliers remove sec­ roded, replace them with new ones. The piston cups ondary piston retainer pin from inside master cylin­ and seals should be replaced when reconditioning a master cylinder.
  • Page 328 MASTER CYLINDER—BRAKES 5-51 secondary piston. Push piston assemblies into bore up INSTALLING MASTER CYLINDER primary piston cup. Carefully work cup into bore Power Brake Equipped men push piston in up to the secondary seal. Care­ (1) Position master cylinder over studs of power fully work lip of primary cup into bore, then push in brake unit, aligning power brake push rod with mas­...

  • Page 329: Master Cylinder

    --------------------------------- - - -------------------------- - ----------- ♦ 5-52 BRAKES—WASTER CYLINDER qnly occur in the secondary chmber and so to deter­ voir caps, wipe caps and reservoir clean to prevent mine if the primary vent port is open, it will be dirt and other foreign matter from dropping into the necessary to pump up the brakes rapidly and, then, If necessary add fluid to bring level to bot­...

  • Page 330: Installation

    MASTER CYLINDER—BRAKES 5-53 roded, replace them with new ones. All caps and seals should be replaced when conditioning a master cylin­ der. When overhauling a master cylinder, use all parts furnished in repair kit. Discard all used rubber parts. ASSEMBLY Before assembling the master cylinder (Fig.
  • Page 331 5-54 BRAKES—HYDRAULIC SYSTEM CONTROL VALVES-------- -------------------------------------------------♦ NU 828E Fig. 6—Tandem Master Cylinder (Disassembled) and observe for a geyser of fluid squirting up in res­ Connect push rod to brake pedal linkage. (3) Connect front and rear brake tubes and tighten ervoirs.
  • Page 332 HYDRAULIC SYSTEM CONTROL VALVES—BRAKES 5-55 ♦—■ HOLD-OFF PROPORTIONING TO FRONT BRAKE OUTLET TO REAR BRAKES VALVE STEM TO FRONT BRAKE PK397B Fig. J—Combination Warning Switch/Hold Off/Proportioning Assembly (Sectional) Typical Cast Iron and braking response is directly proportional to pedal Brake Warning Switch Operation The hydraulic system brake warning switch is used effort.
  • Page 333 12.82"(325.6mm) 12.88"(327mm) Inside Diameter..7.775"(197mm) 8.86"(225mm) 8.86"(225mm) 8.80"(223mm) Type........Ventilated Ventilated Ventilated Ventilated Thickness...... 1.25"(31.75mm) 1.25"(31.75mm) 1.19"(30mm) 1.19"(30mm) Caliper—Make ....Chrysler Chrysler Chrysler Bendix Type........Sliding Sliding Sliding Sliding Piston Diameter..3.10"(78.7mm) 3.10"(78.7mm) 3.10"(78.7mm) 3.38"(85.8mm) Lining—Make ..... CPD1816 CPD1816 ME-D-7123A ME-D-5157 Attachment ......
  • Page 334 Brake Line Tube Nuts, 3/8 or 7/16 ........80-150 125-175 (15.3-21.5) 1/2 or 9/16 ........(162) Bottom attaching bolts ............DISC BRAKE (CHRYSLER) (149) Adaptor Mounting Bolts D150-D250-AD150-PD150....(203) W150, AW150, PW150, W250 ..........(216) D250 H.D., D350 ..............(24.5) Retainer and Anti-Rattle Spring ...........
  • Page 335 5-56 BRAKES—HYDRAULIC SYSTEM CONTROL VALVES- WARNING TO REAR BRAKES TO FRONT BRAKE RY 601 Fig. 2—Combination Warning Switch/Hold Off Assembly—Typical Brass piston and automatically turn off the warning light. brake warning switch piston and opens a bypass in THE VALVE SHOULD NOT BE DISASSEMBLED TO the proportioning unit allowing full rear brake hy- RESET THE PISTON.
  • Page 336 ♦ HYDRAULIC SYSTEM CONTROL VALVES—BRAKES 5-57 disconnected wire at the switch. If the bulb is not HOLD-OFF FRONT SYSTEM 3 FROM MASTER CYLINDER nied out and the wire continuity is proven, replace VALVE SECONDARY PORT > valve and bleed the system. STEM OUTLET PRESSURE After repairing and bleeding the brake system (see...
  • Page 337 12.82"(325.6mm) 12.88"(327mi Inside Diameter..7.775"(197mm) 8.86"(225mm) 8.86"(225mm) 8.80"(223mn Type......Ventilated Ventilated Ventilated Ventilated 1.25"(31.75mm) Thickness ....1.25"(31.75mm) 1.19"(30mm) 1.19"(30mm Chrysler Caliper—Make ..... Chrysler Chrysler Bendix Sliding Type......Sliding Sliding Sliding 3.10"(78.7mm) Piston Diameter..3.10"(78.7mm) 3.10"(78.7mm) 3.38"(85.8mn CPD1816 Lining—Make ....CPD1816...

  • Page 338: Wheel Cylinder

    Brake Line Tube Nuts, 3/8 or 7/16 ........(9.8-18.4) 125-175 1/2 or 9/16 ........(15.3-21.5) (162) Bottom attaching bolts ............ DISC BRAKE (CHRYSLER) (149) Adaptor Mounting Bolts D150-D250-AD150-PD150....(203) W150, AW150, PW150, W250 ..........D250 H.D., D350 ..............(216) (24.5)
  • Page 340 ■hrysler Corporation reserves the right to make changes in design or to Jake 'itions to or improvements in its products without imposing any .s upon itself to install them on its products previously manufac- ithoinU.S.A. Copyright Chrysler Corporation 1982 &20M1082...

  • Page 341: Special Service Tools

    3-70 SPECIAL SERVICE TOOLS...
  • Page 342 □ BRAKES BRAKES CONTENTS Page Page GENERAL INFORMATION......Hydraulic System Control Valves ... 33 Master Cylinders . . . 28*32 SERVICE DIAGNOSIS......SERVICE PROCEDURE......Parking Brake........47 Power Brake (Diaphragm)....... 38 Bendix BX Duo Servo Brake Power Brake (Hydro-Boost)....40 (Rear Drum)........25 Support Plates........37 Bleeding Brake System......
  • Page 343 BRAKES BASIC DIAGNOSIS GUIDE CHART 4 CHART 5 CHART CHART 1 CHART 2 CHART 3 PULL SYMPTOM MISC. COND. ACTUATION POWER NOISE WHEEL BRAKES BRAKE WARNING LIGHT "ON" EXCESSIVE PEDAL TRAVEL-SPONGY PEDAL PEDAL GOES TO FLOOR • STOP LIGHT "ON" ALL THE TIME BRAKES DRAG-FRONT OR ALL REAR BRAKES DRAG BRAKES RELEASE SLOWLY...
  • Page 344 BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS 2 OF 5 RB864 B...
  • Page 345 □ BRAKES BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS 3 OF 5 RB864B...
  • Page 346 BRAKES □ BRAKE CHART 4 BRAKE NOISE DIAGNOSIS “INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED "WAYS" OF CALIPER AND ADAPTER. ***MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMATED OR REDUCED BY ROTATION DRUM (REAR) TWO STUDS ON AXLE FLANGE.
  • Page 347 BRAKES □ BRAKE CHART 6 BRAKE PULL DIAGNOSIS 5 OF 5 RB864 B...

  • Page 348: Bleeding Brake System

    □ BRAKES SERVICE PROCEDURES HYDRAULIC BRAKE SYSTEM (2) Bleed masier cylinder. This can be done on the vehicle or on the work bench. The best method is to disconnect vehicle brake tubes, connect short lengths Servicing the hydraulic system is chiefly a matter of of brake tubing (Tool C-4029) to outer ports, and adjustments, replacement of worn or damaged parts immerse other ends in master cylinder reservoirs.
  • Page 349 BRAKES of pumping pedal and opening bleeder screws. Do not If warning light does not go off after you release pump master cylinder dry! brake pedal, the master cylinder is bad or hydraulic (3) Pressure Bleed. This method of bleeding is system has a serious leak.
  • Page 350 BRAKES □ (1) Correct length, severe surface cracking, pulling, scuffing or worn spots. (Should the casing of the hose be exposed to weather by cracks or abrasions in the rubber hose cover, eventual deterioration of the hose can take place with possible burst failure). (2) Faulty installation to cause twisting, wheel, tire or chassis interference.
  • Page 351 □ 5-10 BRAKES SCREW TO MASTER CYLINDER TO MASTER CYLINDER 150-250 8W" AXLE—SCREW PRIMARY (5/16-18x75) SECONDARY SCREW (5/16-18x75) TO LEFT BRAKE 150-250 9 AXLE—VENT SCREW VIEW D P/O AXLE ASSEMBLY <t> 120 IN.-LBS. (11 N.m) (16 N.m) (13.55 N.m) <§> 95 IN.-LBS. (107 N.m) (13 N*m) <£>...

  • Page 352: General Information

    ---------------------------------------- BRAKES 5-11 end of flaring screw and continue to screw down until tool is firmly seated in tubing. (10) Remove tubing from flaring tool and inspect seat. (11) Clean seat and tube of any lubricant before con­ necting to hydraulic system. DISC BRAKE (Sliding Caliper) INDEX Page...
  • Page 353 5-12 BRAKES effort. Drum brii!»c rcopOiiCc occurs after piston travel, between the piston and the cylinder wall (Fig. 3). The return spring stretch and shoe contact with the drum, adaptor is mounted to the steering knuckle by two spe­ then self energizing tends to multiply pedal effort. cial nylock bolts (Figs.
  • Page 354 BRAKES 5-13 CALIPER BOOT PISTON BRAKE FLUID WHEEL STUD SPINDLE OUTER BEARING BRAKING DISC NU4E Fig. 3—Disc Brake Assembly (Sectional)
  • Page 355 □ 5-14 BRAKES anti rattie spring BRAKE HOSE AND TUBING Fig, 4—Adaptor and Caliper Machined "Ways” and Caliper Retention Inspection of brake hose and tubing should be included in all brake service operations and every sec­ ond oil change. Brake Roughness The hoses should be checked for: The most common cause of brake roughness (or (1) Correct Length, severe surface cracking, pulling...

  • Page 356: Cleaning And Inspection

    □ BRAKES 5-15 should be taken to make sure that the tube and hose (3) During removal and installation of a wheel and mating surfaces are clean and free from nicks and tire assembly, use care not to strike the caliper. burrs.
  • Page 357 □ 5-16 BRAKES------------------------------------- CALIPER ANTI-RATTLE Fig. 9—Caliper Assembly Exploded View until it is bottomed. Watch for possible reservoir over­ flow. (2) Slide new outboard shoe and lining assembly in Fig. 11—Bending Outboard Shoe Retaining Flanges recess of caliper. CAUTION: No free play between brake shoe flanges and caliper flanges (Fig.

  • Page 358: Disassembling Caliper

    □-------------------------------------------------------------------- BRAKES 5-17 REMOVING CALIPER FROM VEHICLE It will be necessary to remove the caliper to install a 'w piston seal and boot, i) Raise the vehicle on jackstands or hoist. (2) Remove front wheel covers and wheel and tire assemblies.

  • Page 359: Assembling Caliper

    5-18 BRAKES □ CALIPER Fig. 15—Honing Piston Bore increased more than .002 inch (.050 mm). If the bore does not clean up within this specification, a new caliper housing should be installed. Black stains on the Fig. 17—Installing Piston Through Boot piston are caused by the piston seal and will do no When using hone C-4095, coat the stones and harm.

  • Page 360: Installing Caliper

    □ BRAKES 5-19 (6) Position dust boot in counterbore. Using sure all air bubbles have escaped; replenish brake fluid hammer and Tool C-4691 with handle C-4171, drive the in master cylinder. Bleed brakes as described under boot onto the counterbore (Fig. 18). "Bleeding Brakes”...
  • Page 361 ---------------------------------------------------------------------- D 5-20 BRAKES---------------------------------------- Inspection Diagnosis contact if ridges are not removed before installation of ’efore refinishing or refacing a braking disc, the disc new lining (pads). buould be checked and inspected for the following con- Some discoloration or wear of the disc surface is nor­ ditions.
  • Page 362 □ BRAKES 5-21 warped or there is a complaint of brake roughness the REFINISHING (REFACING) BRAKING DISC rotor should be refaced (Fig. 2). When refacing a disc brake rotor the required .004 Resurfacing Braking Disc (.1016 mm) TIR (Total Indicator Reading) and .0005 operation can be used when the disc surface is (.127 mm) thickness variation MUST BE MAIN­...

  • Page 363: Brake Drum Removal

    5-22 BRAKES □ tion to the manufacturer's instructions is required. If Example: the disc is not mounted properly the runout will be Minimum Allowable Thickness worse after refacing than before refacing. .940 (23.8mm) The use of a double straddle cutter which machines Allow for Wear .030 (.762mm) both sides of the disc at the same time is highly recom­...
  • Page 364 □ BRAKES 5-23 TAB OF ANTI­ SPECIAL TOOL SECONDARY SHOE (REMOVING AND RATTLE SPRING AND LINING BEHIND SHOE INSTALLING) WEB! SHOE RETURN SPRINGS SPECIAL TOOL SPRING NAIL LEVER RETAINER SPRING PRIMARY SHOE NU24JB AND LINING" SHOE TO SHOE ADJUSTING SPRING LEVER NU243C Fig.
  • Page 365 □ 5-24 BRAKES Fig. 6—Shoe Contact Area on Support Fig. 7—Installing Brake Shoes (Left Rear) a single cut should be limited to .005 inch (.127 mm). anchor plate over anchor, then install eye of adjuster When the entire braking surface has been cleaned a cable over anchor.
  • Page 366 □ —BRAKES 5-25 BENDIX BX DUO-SERVO BRAKE INDEX Page Page General Information........... Brake Shoe Installation........Service Procedure..........Brake Shoe Removal........Brake Drum Installation......... Cleaning and Inspection........Brake Drum Removal........Drum Refacfng............ GENERAL INFORMATION The Bendix BX Duo-Servo is a basic Duo-Servo single a coil spring-hold down pin combination (Fig.
  • Page 367 BRAKES 5-26...
  • Page 368 BRAKES 5-27 HOLD DOWN PIN SHOE HOLD DOWN SPRING When the entire braking surface has been cleaned a final cut of .001 inch (.025) will assure a good drum surface providing the equipment used is capable of giv­ ing the precision required for resurfacing brake drums.
  • Page 369 5-28 BRAKES > PY1243 Fig. 6—Removing or Installing Upper Shoe-to-Shoe Fig. 8—Removing or Installing Shoe Assembly Spring (Rear) (Rear) BRAKE DRUM INSTALLATION Rear (1) Position drum on axle housing. (2) Install bearing and inner nut. Adjust bearin; (See Group 3) in this manual. (3) Install locking washer and outer nut.

  • Page 370: General Information

    □ BRAKES 5-29 GENERAL INFORMATION ''he aluminum master cylinders with a black nylon der is also connected to the warning switch/Hold-Off ^rvoir has replaced cast iron master cylinders on valve and the front brakes. This system is referred to as primary.
  • Page 371 □ 5-30 BRAKES Fig. 1—Master Cylinder (Cutaway View) REMOVE AND REPLACE RESERVOIR roded, replace them with new ones. Before disassembling the master cylinder (Fig. 1) BLEEDING MASTER CYLINDER clean outside of reservoir and master cylinder housing. (1) Remove reservoir caps and empty the brake Before installing the master cylinder on vehicle, it fluid from reservoir.
  • Page 372 BRAKES 5-31 Bleeding the Brake System in SERVICE PROCE­ DURES. (5) Connect stop lamp switch mounting bracket and adjust. (See Stop Lamp Switch Adjustment in "Service Adjustments”.) TESTING MASTER CYLINDER Be sure that the master cylinder vents at both ports. This can be done by applying the pedal lightly with the engine running (power brakes) and observing for fluid disturbance in the reservoirs.

  • Page 373: Tandem Master Cylinder

    5-32 BRAKES stored in a tightly closed container, to avoid contami- contaminate the brake fluid. Seal damage wl nation with foreign matter or moisture. result. CAUTION: Do not allow petroleum base fluid to TANDEM MASTER CYLINDER (Hydro*Boost) INDEX Page Installation . General Information........

  • Page 374: Installation

    □ -BRAKES 5-33 (3) Connect front and rear brake tubes and tighten COVER securely. COVER (4) Bleed entire brake system see "Bleeding Brake GASKET System” section of this group. SNAP After bleeding the brake system, check to see that RING MASTER CYLINDER master cylinder is venting at both ports.
  • Page 375 5-34 BRAKES □ To test the service brake warning system, raise the FROM MASTER CYLINDER lar on a hoist and open a wheel cylinder bleeder while SWITCH ASSEMBLY (FOR FRONT DISC) a helper depresses the brake pedal and observes the FROM MASTER OUTLET TO CYLINDER...
  • Page 376 BRAKES 5-35 Continue this bleeding operation on the other wheels starting with the left rear wheel, then the right front and finishing with the left front wheel. ' necessary, repeat this bleeding operation if there is indication (a spongy brake pedal or warning light) of air remaining in the hydraulic system.
  • Page 377 5-36 BRAKES □ WHEEL CYLINDERS INDEX Page Page Assembling Wheel Cylinders......Installing Wheel Cylinders........ Disassembling Wheel Cylinders....... Removing Wheel Cylinders........ GENERAL INFORMATION FORMED PISTON STOPS Models using BX Duo-Servo Brakes (B-350) have wheel cylinder piston stops formed in the support plate (Fig.
  • Page 378 5-37 rakes PISTON REAR—HOUSING PUSH ROD SPRING PRESS-ON BOOT PRESS-ON BOOT EXPANDERS PISTON 5/16" BLEED SCREW PUSH ROD PF449A Fig. 2—Rear Wheel Cylinder (Disassembled) SUPPORT PLATES INDEX Page Page illation.............. Removal (Rear) (1) With wheel and brake drum removed, remove support attaching nuts and washers.

  • Page 379: Power Brake (Diaphragm)

    5-38 BRAKES POWER BRAKE—BENDIX INDEX Page Pag> General Information..........Service Procedures..........GENERAL INFORMATION The diaphragm type power brake is a self-contained port seal is a part of the valve body attached to thi diaphragm assembly. The atmospheric port is a part o vacuum hydraulic power braking unit.
  • Page 380 □ BRAKES 5-39 SERVICE PROCEDURES Removal BRAKE PEDAL AND LINKAGE ' Disconnect vacuum hose from check valve. Removal (Fig. 2) ^) Remove master cylinder to booster mounting (1) Remove bolt holding master cylinder push rod to nuts. pedal. (3) Remove booster to hub and bellcrank pivot bolt. (2) If vehicle is equipped with standard transmis­...

  • Page 381: Specifications

    5-40 BRAKES POWER BRAKE—BENDIX HYDRO-BOOST INDEX Page Page Cleaning and Inspection......... General Information ........... Disassembly....Service Diagnosis..........Service Procedures........... Installation............Accumulator Overhaul........Removal............Bleeding Hydro-Boost and Power Steering Specification............Hydraulic System........Tightening Reference........Booster Power Section........Special Service Tools........Assembly............ GENERAL INFORMATION The valve bore in the housing contains a spool and B350 school bus vehicles use the Bendix Hydraulic...

  • Page 382: Service Diagnosis

    □ BRAKES 5-41 The accumulator is charged with fluid when the The forward movement of the spool diverts addi- power steering valve is activated by turning the steer­ ^onal hydraulic fluid into the cavity behind the booster ing wheel or when the hydraulic brake booster is to build up hydraulic pressure in this area.
  • Page 383 5-42 BRAKES Possible Cause Correction Condition GRABBY BRAKES Broken spool return spring Replace spring Faulty spool action cause by contamination Inspect, clean and replace all booster seals in system BOOSTER CHATTERS- Power steering pump belt slips Tighten belt PEDAL VIBRATES Low fluid level in power steering pump res­...
  • Page 384 □------------------------------------------------------------------- ----- BRAKES 5*43 Bleeding Hydro-Boost and Power Steering (4) Position booster in a vise equipped with soft Hydraulic System jaws, bracket end up. Using a chisel and hammer cut the nut holding mounting bracket to the power section. (1) Fill hydraulic pump reservoir to proper level lh MOPAR Hydro-Boost Power Steering Fluid, Part Do not damage threads on booster hub.
  • Page 385 5-44 BRAKES □ Fig. 4—Removing Spool Plug Retainer Ring Fig. S—Removing Screws to Separate Housings a spare tube nut in each port to seat tube seat. damage. Discoloration of the spool or bore, particu­ Remove spare nuts and make sure ports are clean larly in the grooves, is not harmful.
  • Page 386 -BRAKES 5-45 <4 .(ft , o>...
  • Page 387 □ 5-46 BRAKES Fig. 12—Installing Piston Assembly Using Fig. 10—Installing Seals Using Tool C-4394 Tool C-4393 Tool C-4394 with clean steering fluid. Slide seals on tool (10) Align tab in booster bracket with slot in with the lip of the cups toward open end of tool. Slide threaded portion of booster hub.

  • Page 388: Parking Brake

    □ BRAKES 5-47 TORQUE WRENCH HYDRO-BOOST TOOLS ■ BOOSTER PN454 C-4395 Fig. 14—Torqulng Mounting Nut Using ToolC-4395 PN4J5 C-4393 C-4396 ■ ACCUMULATOR OVERHAUL Fig. IS—Hydro-Boost Tools Disassembly Assembly WARNING: EXTREME CARE MUST BE TAKEN (1) Using clean power steering fluid as a lubricant WHEN SERVICING THE ACCUMULATOR AS IT CON­...

  • Page 389: Parking Brake Adjustment

    □ 5-48 BRAKES--------------- GENERAL INFORMATION The wheel brake cables are joined together by a for­ The rear wheel brakes also act as parking brakes, ward brake cable and equalizer extending to the park­ -hey are mechanically operated by a lever and strut ing brake pedal (Figs.
  • Page 390 BRAKES 5-49 Fig. 2—Parking Brake Routing and Adjustment—B3, B3S0 cies corrected (rust, kinks in cables, worn or bent components, etc.) to insure proper adjustment. (1) Raise vehicle high enough to gain access to the equalizer and cable adjustment. Release control. (2) Loosen adjustment until there is slack in each cable.
  • Page 391 5-50 BRAKES Fig. 4—Parking Brake Equalizer and Adjuster—B350 Fig. 5—Removing Brake Cable from Support a small screwdriver push ball end of cable out of lever assembly then slide cable out of assembly. (4) Remove brake shoe retaining springs (B-150 and (5) Raise hood and carefully remove cable.
  • Page 392 ------ ;----------------------------------- SPECIFICATIONS 5-51 SPECIFICATIONS SERVICE BRAKES B-350 B-350 FRONT DISC B-150 B-250 W/3600#F/A W/4000#F/A Caliper Chrysler Chrysler Chrysler Chrysler Make........ Sliding Caliper Sliding Caliper Sliding Caliper Sliding Caliper Type........ Piston Diameter....3.10" 3.10" 3.10" 3.10" (78.74mm) (78.74mm) (78.74mm) (78.74mm)

  • Page 393: Parking Brakes

    □ 5-52 SPECIFICATIONS PARKING BRAKES Rear Wheel B-150 B-250 B-350 B-350 W/4000 #F/A Size........10" x 2.5" 10" x 2.5" 12" x 2.5” 12" x 3.0" (254 x 63.5mm) (254 x 63.5mm) (305 x 63.5mm) (305 x 76.2mm) 12” x 2.5 (305 x 63.5mm) Lever........
  • Page 394 SPECIAL TOOLS 5-53 SP-5195 C-4578 ADAPTER FOR C-3496B PF555A HYDRAULIC SYSTEM CONTROL VALVES-SPECIAL TOOLS DISC BRAKE (SLIDING CALIPER) SPECIAL TOOLS C-4007A PF558...
  • Page 395 □ 5-54 TIGHTENING REFERENCE TIGHTENING REFERENCE Inch Foot Pounds Pounds 20 to 40 27 to 54 Bellcrank Push Rod Nuts..Hydro-Boost Brake Booster Attaching 21 to 28 190 to 250 Nuts........Brake Booster Bracket 27 to 54 Attaching Nuts....20 to 40 Booster Bracket to Booster 95 to 120 128 to 163...
  • Page 396 /[chassis &Body feiplomat Mirada JSran Fury Cordoba jNeWYorker Imperial...
  • Page 397 GROUP INDEX Introduction, General Information Lubrication and Maintenance________ ;_________________ HHI Front Suspension and Steering Linkage Rear Axle Foreword Brakes This Service Manual has been written with the latest service information available at the time of publica­ Cooling System tion. It is divided into various group categories. Each group contains diagnosis, disassembly repair and in­...

  • Page 398: Power Brake

    BRAKES' BRAKES v'dv?.v- CONTENTS Page BRAKE DISC (ROTOR)......... POWER BRAKES ........BRAKE EQUIPMENT APPLICATION..SERVICE ADJUSTMENTS....SERVICE DIAGNOSIS ........ DISC BRAKES..........SPECIAL TOOLS ........DRUM BRAKES .......... SPECIFICATIONS........HYDRAULIC SYSTEM CONTROL VALVES MASTER CYLINDER TIGHTENING REFERENCE......Aluminum ..........WHEEL CYLINDERS ........PARKING BRAKES ........

  • Page 399: Wheel Brake

    BRAKES holding adjusting lever out of engagement, back off of the adjuster star wheel can be observed if the auto­ star wheel to insure a free wheel with no brake shoe matic adjuster is working properly. If one or more ad­ drag.
  • Page 400 ------------------------------------- ------------- BRAKES Brake System Bleeding Procedures Bleeding Master Cylinder). brake tubes are con­ After All disc brake vehicles are equipped with a nected, have helper apply force to pedal while both '•’■''ssure hold-off valve. The valve is located (in the tube nuts are cracked to release any air and then re­...
  • Page 401 -------------------------------------------- BRAKES end of the hose onto caliper, or rear axle housing tee. WHEEL STUD NUT TIGHTENING The intermediate bracket should then be bolted to the The tightening sequence and torquing of the wheel suspension “k” member. The hose should then be at­ 1 nuts is of great importance to insure efficient tached to the hose bracket in a manner to give mini­...
  • Page 402 BRAKES...
  • Page 403 ■ BRAKES-------------------------------- (4) Slide switch assembly toward pedal blade until STOP LAMP SWITCH ADJUSTMENT switch plunger is fully depressed against spacer gauge The stop lamp (or stop lamp/speed control) switch (on heavy duty or stop light/speed control switches, .d mounting bracket assembly is attached to the depress plunger until switch body contacts spacer brake pedal bracket.
  • Page 404 BRAKES BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 CHART 6 SYMPTOM MISC. COND. ACTUATION POWER NOISE WHEEL BRAKES PULL BRAKE WARNING LIGHT "ON" EXCESSIVE PEDAL TRAVEL-SPONGY PEDAL PEDAL GOES TO FLOOR STOP LIGHT "ON" ALL THE TIME BRAKES DRAG-FRONT OR ALL REAR BRAKES DRAG BRAKES RELEASE SLOWLY...
  • Page 405 BRAKES BRAKE CHART 2 ACTUATION DIAGNOSIS 2 OF 5 RB864...
  • Page 406 BRAKES BRAKE CHART 3 TROUBLESHOOTING POWER BRAKE DIAGNOSIS 3 OF 5 RB864 A...
  • Page 407 « 5-TO BRAKES BRAKE CHART 4 BRAKE NOISE DIAGNOSIS '•INSTALL "O" RINGS (AROUND ADAPTER) BETWEEN MACHINED "WAVS" OF CALIPER AND ADAPTER. •‘•MOPAR MULTIPURPOSE LUBRICANT, PART NUMBER 2932524, OR EQUIVALENT. BRAKE CHART 5 WHEEL BRAKES DIAGNOSIS PULSATION CAUSED BY REAR BRAKES MAY BE ELIMATED OR REDUCED BY ROTATION DRUM (REAR) TWO STUDS ON AXLE FLANGE.
  • Page 408 BRAKES 5-11 BRAKE CHART 6 BRAKE PULL DIAGNOSIS 5 OF 5 RB864A...

  • Page 409: Drum Brakes

    5-12 DRUM BRAKES DRUM BRAKES INDEX Page Page Drum Refacing Recommendations......brake Drum Removal ..........General Information ..........Brake Shoe Removal..........Service Diagnosis ............ Brake Drum Installation ......... Special Tools ......:....... Brake Shoe Installation........... Cleaning and Inspection ......... GENERAL INFORMATION lower ends of the brake shoes are connected by a All drum brake applications are two shoe, internal tubular star wheel adjusting screw (Figs.
  • Page 410 DRUM BRAKES 5-13 TAB OF ANTI- SHOE SH0E SECONDARY SHOE RATTLE SPRING RETURN RETURN AND LINING (BEHIND SHOE WEB) <~''NG ANCHORvSPR|NG CABLE PLATE GUIDE TAB (3) SHOE RETAINERS, SPRING AND NAIL ASSEMBLIES SPECIAL, TOOL ANTI­ RATTLE SPRING STRUT PARKING BRAKE LEVER SECONDARY Fig.
  • Page 411 BRAKES 5-14 DRUM •m SHOE ANCHOR PLATE RETURN SPRING ADJUSTER TAB OF ANTI- CABLE RATTLE SPRING STRUT PARKING BRAKE CABLE PRIMARY SHOE NU245B AND LINING Fig. 8—Removing or Installing Parking Brake Strut and Spring and into slot in parking brake lever. Slide anti-rattle spring over free end of strut (Fig.
  • Page 412 m------------- ------------------------------------------------------------------------------------------------------------------------- -- —-—------------—- -------- MASTER CYLINDER (ALUMINUM) 5-15 both, hole in guide, and hole in web. Using Tool C- shoe web. Install adjusting lever under spring and 3785, install remaining spring loops over anchor. (Be over pivot pin. Slide lever slightly rearward to lock in position.
  • Page 413 5-16 MASTER CYLINDER (ALUMINUM) Fig. 1—Aluminum Master Cylinder (Exploded View) provide best brake performance. eating proper fluid level. If adding fluid is neces­ Use of a brake fluid sary, that may have a lower initial boiling point, such as before removing the reservoir caps, wipe caps and reservoir clean to prevent dirt and other foreign fluid identified as 70R1 or unidentified as to specifica If necessary,...
  • Page 414 HYDRAULIC SYSTEM CONTROL VALVE 5-17 (4) Remove bleeding tubes from cylinder, plug Fig. 3—Bleeding Master Cylinder outlets to prevent spillage and install caps. (5) Remove from vise and install master cylinder Connect front and rear brake tubes and tighten on vehicle. to 170 inch-pounds (19 N-m).
  • Page 415 5-tB HYDRAULIC SYSTEM CONTROL VALVE HOID-OFF WARNING SWITCH PROPORTIONING Fig. 1—Combination Warning Switch/Hold Off/Proportioning Valve Assembly (Sectional View) leased. After the system is repaired and bled (see “Valve Application Chart”. During any service “Bleeding Brake System” in service adjustments), a procedures identify valve assemblies by part number as well as hold off/cut in (PSI) and split point (PSI).
  • Page 416 VALVE 5-ig HYDRAULIC SYSTEM ontrol ■■■■■■■■..............'■ pressure transmitted to the rear brakes will be lower to overcome the return springs and begin to contact than to the front brakes to prevent premature rear the drums. This valve keeps the output pressure to wheel lock-up and skid.
  • Page 417 5-20 WHEEL CYLINDERS Inlet Pressure and brake valve assembly (Fig. 2). Split Point(PSI)/ From Outlet Pressure (2) Install the second gauge of set C-4007A to the Slope Master Cylinder To Rear Brakes brake outlet port between valve assembly and the 220/2.3 1000 500-600...
  • Page 418 WHEEL CYLINDERS 5-21 REAR-HOUSING PUSH ROD PISTON PRESS-ON BOOT PF449A Fig. Wheel Cylinder, 10 and 11 Inch Brakes 2—Rear (2) Using a suitable tool such as an aircraft type that have light scratches, or show signs of corrosion, hose clamp compress the flared legs of cable retainer can usually be cleaned with crocus cloth, using a cir­...
  • Page 419 ■ 5-22 PARKING BRAKES To remove and install brake support assemblies on (4) Insert parking brake cable into support plate 8-1/4 inch axles follow the same general procedure as and attach cable to parking brake lever. above, except that internal locks must be removed to 15) Install brake shoes on support plate.
  • Page 420 PARKING BRAKES 5-23...
  • Page 421 5-24 POWER BRAKES LEVER ASSEMBLY cowi PACKING BRAKE SIDE INNER SWITCH AND (REFERENCE) SCREW INSTRUMENT PANEL LOWER SCREWS Fig. 2—Removing Brake Cable from Support Plate (2) Using a screwdriver, force cable housing and at­ taching clip forward out of body crossmember. GROMMET GROMMET ■...
  • Page 422 POWER BRAKES 5-25 SERVICE PROCEDURES °0WER BRAKE VACUUM HOSE 105 degree bend, cut straight section of hose for proper length. hose replacement refer to chart and Figure 2 for application by car line and engine for proper hose type and length. NOTE: Preformed hose will have a E5-E 'A"...
  • Page 423 5-26 POWER BRAKES POWER BRAKE ASSEMBLY ALL MODELS (Bendix) SERVICE PROCEDURES to pass over end of brake pedal pin and pull retaine REMOVING POWER BRAKE UNIT clip from pin. Discard retainer clip. (4) Remove lower pivof retaining bolt and nu1 (1) Remove nuts attaching master cylinder to power brake unit.
  • Page 425 5-26 DISC BRAKES .« DISC BRAKES INDEX Page Page Assembling Caliper ..........Installing Caliper............Brake Hose and Tubing........... Removing Caliper from Vehicle ....... Brake Shoe Installation ........... Routine Maintenance....-........Brake Shoe Removal ..........Service Checks............Cleaning and Inspection ........... Service Diagnosis ............Disassembling Caliper..........
  • Page 426 DISC BRAKES 5-29 PISTON BRAKE FLUID WHEEL STUD SPINDLE OUTER BEARING BRAKING DISC NU4E Fig. 3—Disc Brake Assembly-Sectional...
  • Page 427 5-30 DISC BRAKES — ---------------------------------------------------------------------------------------------- ■———---------------------------■ moves inboard pulling the outer shoe and lining caliper assembly must be removed in order to inspect against the outer surface of the disc. Thus, providing a (Refer to "Brake Shoe Re­ the inner wheel bearings. lamping force (Fig.
  • Page 428 ---------------------- --- ------------- ------------------------------------DISC BRAKES 5-31 ■ -—„ ■■ ------------ ■ ■■■■■ SERVICE CHECKS Check and adjust or replace loose, worn or broken parts. (1) Check the master cylinder fluid level at each (4) Check lining wear at least every 10,000 miles rication period.
  • Page 429 5-32 DISC BRAKES Fig. —Caliper Finger and Outboard Shoe Retainer Flange Fig. 7—Removing or Installing Inboard Shoe (2) Slide new outboard shoe and lining assembly in Cleaning and Inspection recess of caliper. CAUTION: No free play between Check for piston seal leaks (evident by brake fluid brake shoe flanges and caliper fingers (Fig.
  • Page 430 --------------------------------------- DISC BRAKES 5-33 — ways be installed on top of the retainer spring plate. (Fig. 1). (6) Pump brake pedal several times until a firm pedal has been obtained. (7) Check and refill master cylinder reservoirs (if necessary) with DOT 3 brake fluid as required. It should not be necessary to bleed-the system after shoe and lining removal and installation.
  • Page 431 ■ 5-34 DISC BRAKES leave brake hose connected to tube at frame mounting bracket. See "Disassembling Caliper". Plug brake hose connector to prevent loss of fluid, or prop brake pedal to any position below first inch of travel. (4) Remove retaining screw, retaining clip (and anti-rattle spring) that attach caliper to adapter (Fig.
  • Page 432 DISC BRAKES 5-35 —. this specification, a new caliper housing installed. Install a new piston if the old one or severely worn or if the bore has 'Ud, scored Soned. When stones using Hone C-4095, coat the with brake honing the bore fluid.
  • Page 433 5-36 BRAKING DISC (ROTOR) linings are installed in their original position. (1) Slide new outboard shoe and lining assembly in recess of caliper. CAUTION: No free play between brake shoe flanges and caliper fingers (Fig. 9) should exist (which might cause brake shoe rattle). If free play is evident by vertical shoe movement after installation, remove shoe from caliper and bend flanges (Fig.
  • Page 434 ------------------------------------------------------------------------------------- —--------- —BRAKING DISC (ROTOR) 5-37 Thickness variation in a disc can also result in pedal tion can be caused by extreme heat and abuse of the pulsation, chatter and surge due to variation in brake brakes, output when disc section is uneven. Dishing or distor- SERVICE PROCEDURES .0005 of an inch remove and resurface the disc or CHECKING BRAKING DISC FOR RUNOUT...
  • Page 435 5-38 BRAKING DISC (ROTOR) Remove the least amount of metal necessary to cor­ quired. The collets, shafts and adapters on the It rect the condition and remove an equal amount from and the bearing cups in the rotor MUST be clean free from any chips or contamination.

  • Page 436: Specifications

    SPECIFICATIONS 5-39 turer’s instructions is required. If the disc is not mounted properly the run-out will be worse after re­ facing than before refacing. he use of a double straddle cutter which machines ^h sides of the disc at the same time is highly recom­ mended.
  • Page 437 5-40 TIGHTENING REFERENCE DISC BRAKE—FRONT (Cont.) (All Single Piston)___________________ All Models Thickness ......... "/ " Parallelism—Total Variation in Thickness in 360° of Rotation....0005" SHOE & LINING Riveted Type........... Thickness—Shoe & Lining- Inner—Nominal ..694" Outer—Nominal ..535" 7.57 Sq. In. Braking Area—Inner Shoe.....
  • Page 438 ----------------------------- ---------------- BRAKES—SPECIAL TOOLS 5-41 BRAKE SERVICE-SPECIAL TOOLS (REAR WHEEL DRIVE) C-3339 RB837...
  • Page 439 DAIMLERCHRYSLER corp DOCUMENTS BOOK #15 DaimlerChrysler Corporation National Asbestos Program 16750/078601...

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