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1. 80bbc364 Fig 54 Proportioning Valves On Master Cylinder 1 RIGHT FRONT BRAKE TUBE 2 LEFT FRONT BRAKE TUBE 3 LEFT REAR BRAKE TUBE 4 REAR PROPORTIONING VALVES 5 RIGHT REAR BRAKE TUBE 3 Unscrew the Proportioning valve from the mas ter cylinder PL REMOVAL AND INSTALLATION Continued INSTALLATION 1 Lubricate the O ring on the proportioning valve Make sure the O ring on the proportioning valve is new 2 Install the proportioning valve in its master cylinder port Tighten the proportioning valve to a torque of 40 N m 30 ft Ibs 3 Connect the brake tube to the proportioning valve Fig 54 Tighten the tube nut to a torque of 17 N m 145 in Ibs 4 Remove the brake pedal holder Fig 53 5 Bleed the affected brake line See BASE BRAKE BLEEDING in the SERVICE PROCE DURES section in this service manual group 6 Road test the vehide to ensure proper opera tion of the brakes BRAKES TUBES AND HOSES NOTE Brake hoses for each brake are unique and are not interchangeable Always use Mopar replacement brake hoses to ensure quality correct length and superior fatigue life Care should be taken to make sure that the tube and hose mating surfaces are dean and free from nicks and burrs Use new copper seal washers on all connections using banjo bolts and tighten all the fittings to their specified torques Follow the procedures in the next three paragraphs to reduce the potential
2. ATO li PSG ol NG AK P SIN dg 6 OT 9505 238 Fig 22 Brake Pedal Holding Tool 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL 2 Use the figure shown to determine which pro portioning valve needs to be tested Fig 21 3 Remove the hydraulic brake tube from the pro portioning valve controlling the rear wheel of the vehicle that has premature wheel skid 4 Remove the proportioning valve from its outlet port on the master cylinder PL CAUTION Be sure the pressure test fittings being installed into master cylinder and proportioning valve have the correct thread sizes needed 5 Install the Brake Pressure Adapters Special Tool 8644 and 6805 3 onto the proportioning valve Fig 23 6805 3 80bb e369 Fig 23 Tools On Valve 1 PROPORTIONING VALVE 6 Install the proportioning valve with tools back into the outlet port on the master cylinder 7 Attach a Pressure Gauge Special C 4007 A to each pressure adapter Fig 24 O Tool 9505 62 Fig 24 Pressure Gauge Set 1 SPECIAL TOOL C 4007 A 8 Remove the brake pedal holding tool Bleed any air out of the pressure gauge hoses at the pressure gauge 9 With the aid of a helper apply pressure to the brake pedal until the reading on proportioning valve inlet gauge is at the target in
3. 9405 39 Fig 89 Brake Flex Hose At Wheel Cylinder 1 BRAKE SUPPORT PLATE 2 WHEEL CYLINDER ATTACHING BOLTS 3 REAR BRAKE FLEX HOSE TUBE 4 WHEEL CYLINDER ASSEMBLY 9 Remove the parking brake actuator lever from the parking brake cable 10 Position a 1 2 inch wrench over the retainer fingers on the end of the parking brake cable Fig 92 Compress the cable housing retaining fingers with the wrench then pull the cable housing out of the support plate Remove the wrench as the parking brake cable retainer is freed from the mounting hole in the brake support plate PL REMOVAL AND INSTALLATION Continued Fe EN ay Fig 90 Hub And Bearing Dust Cap 1 HUB BEARING ASSEMBLY 2 DUST CAP 1G il Ge 80aa4b73 BRAKES 5 47 9305 115 Fig 92 Removing Park Brake Cable From Support Plate 1 WRENCH 2 CABLE HOUSING RETAINER 80aa4b74 Fig 91 Rear Hub And Bearing Retaining Nut 1 RETAINING NUT 2 SPINDLE 3 HUB BEARING ASSEMBLY 3 PARK BRAKE CABLE 4 SUPPORT PLATE 11 Remove the 4 brake support plate mounting bolts and washers Separate brake support plate from rear suspension knuckle 12 Remove the brake wheel cylinder attaching bolts 13 Remove the brake wheel cylinder from the brake support plate INSTALLATION 1 Install a new O ring at the mating surface of the wheel cylinder to brake support plate NOTE When installing wheel cylinder o
4. 21 Road test the vehicle to ensure proper opera tion of the brakes WITH MANUAL TRANSAXLE REMOVAL 1 Remove the instrument panel Refer to the INSTRUMENT PANELS AND SYSTEMS group in this service manual for the required procedure 2 Depress and hold the brake pedal while rotat ing the brake lamp switch Fig 39 in a counterclock wise direction approximately 30 degrees 3 Pull the switch rearward and remove it from its mounting bracket 4 Disconnect the clutch cable from the dutch pedal spacer Fig 41 GION S WA B0bodeed Fig 41 Clutch Cable Connection 1 SNAP RING 2 CLUTCH PEDAL SPACER 3 CLUTCH PEDAL 4 CLUTCH CABLE PL 5 Disconnect the wiring harness connector going to the clutch pedal switches Fig 42 80bc4eeb Fig 42 Wiring Harness Connector 1 UPSTOP SWITCH 2 CLUTCH PEDAL 3 INTERLOCK SWITCH 4 CONNECTOR 6 Remove the clip securing the power brake booster input rod to the brake pedal Fig 39 Remove the input rod from the brake pedal 7 Remove the four nuts fastening the brake pedal bracket to the power brake booster Fig 40 8 Remove the two nuts fastening the brake pedal bracket to the instrument panel support Fig 40 9 Remove the brake pedal assembly 10 The pedal can be removed from it s bracket by grinding off the peened end of the shaft removing the shaft pedal and bushings A service parts pack age is available to
5. 15 Road test the vehicle to make sure the brakes operate correctly 5 48 BRAKES REMOVAL AND INSTALLATION Continued PARKING BRAKE LEVER WARNING THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 25 POUNDS DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY WARNING WHEN REPAIRS TO THE PARKING BRAKE LEVER OR CABLES ARE REQUIRED THE AUTOMATIC ADJUSTER MUST BE LOADED AND LOCKED OUT TO AVOID POSSIBLE INJURY THE LEVER ADJUSTMENT MECHANISM CAN BE LOADED AND LOCKED OUT AS OUTLINED IN THIS PROCEDURE REMOVAL 1 Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released 2 Fully apply the parking brake lever then shift the transmission into neutral 3 Remove the screws attaching the center con sole then remove the center console 4 Lower the parking brake lever handle to the released position 5 Grasp the parking brake lever output cable by hand and pull upward Continue pulling on the cable until a pin punch can be inserted through the hole in the lever mechanism sector gear and the hole in the right side of its mounting bracket Fig 93 This will lock the parking brake auto
6. Fig 18 Checking Hub Runout 1 HUB SURFACE 2 SPECIAL TOOL C 3339 3 SPECIAL TOOL SP 1910 RN199 Fig 17 Marking Rotor and Wheel Stud 1 CHALK MARK Hub runout should not exceed 0 08 mm 0 003 inch If runout exceeds this specification the hub must be replaced Refer to the SUSPENSION group Fig 19 Index Rotor And Wheel Stud in this service manual for the replacement procedure 1 CHALK MARK If the hub runout does not exceed this specifica tion install the rotor back on the hub aligning the If runout is not within specifications reface or chalk marks on the rotor with a wheel mounting replace the brake rotor Refer to SERVICE PROCE stud two studs apart from the original stud Fig 19 DURES in this section of this group for information Tighten nuts in the proper sequence and torque to on brake rotor machining specifications Recheck brake rotor runout to see if the runout is now within specifications PL DIAGNOSIS AND TESTING Continued BRAKES 5 15 BRAKE ROTOR LIMITS Minimum Rotor Thickness Rotor Thickness Braking Rotor Front Rotor 21 87 22 13 mm 0 861 0 871 in TIR Total Indicator Reading Measured On Vehicle BRAKE DRUM With the drum off the vehicle measure the drum for diameter variation oval shape The diameter variation of the drum braking surface must not exceed either 0 0635 mm 0 0025 inch in 30 or 0 0889 mm 0 0035 inch in 360 Measure brake drum ru
7. Installer Dust Boot C 4689 8011442 Dial Indicator C 3339 GO dara Gauge Set C 4007 A Tubes Master Cylinder Bleed 8358 PL ANTILOCK BRAKE SYSTEM TABLE OF CONTENTS page DESCRIPTION AND OPERATION ANTILOCK BRAKE SYSTEM OPERATION 65 ANTILOCK BRAKE SYSTEM COMPONENTS 66 ELECTRONIC BRAKE DISTRIBUTION 69 TRACTION CONTROL SYSTEM 70 HYDRAULIC CIRCUITS AND VALVE OPERATION saraaa henna Cae ae AE 71 DIAGNOSIS AND TESTING SERVICE WARNINGS AND CAUTIONS 74 ABS GENERAL DIAGNOSTICS INFORMATION 74 ABS WIRING DIAGRAM INFORMATION 74 ABS VEHICLE TEST DRIVE 74 ABS ELECTRONIC DIAGNOSIS 75 TONE WHEEL 0 0 00 76 BRAKE FLUID CONTAMINATION 76 SERVICE PROCEDURES BRAKE FLUID LEVEL CHECKING 77 DESCRIPTION AND OPERATION ANTILOCK BRAKE SYSTEM OPERATION This section covers the physical and operational descriptions and the on car service procedures for the Mark 20e Antilock Brake System ABS with traction control It is the only antilock brake system available on this vehicle The purpose of the antilock brake system is to pre vent wheel lockup under braking conditions on virtu ally any type of road surface Antilock braking is desirable because a vehicle that is stopped without locking the wheels retains directional stability and some steering capability This allows the driver to retain greater control of th
8. 2 BRAKING DISC 3 DISC BRAKE CALIPER 6 Remove the disc brake caliper from the steer ing knuckle The caliper is removed by first tipping either the top right side caliper or bottom left side caliper of the caliper away from the brake rotor 4 STEERING KNUCKLE BRAKE ABUTMENT PL REMOVAL AND INSTALLATION Continued 4 Install the caliper guide pin bolts and tighten them to a torque of 22 N m 192 in Ibs Fig 57 5 Install the banjo bolt connecting the brake hose to the brake caliper Fig 56 Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting Install new wash ers if they are worn or damaged at all Thread the banjo bolt into the caliper and tighten it to a torque of 48 N m 35 ft Ibs 6 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 7 Lower the vehicle 8 Remove the brake pedal holding tool 9 Bleed the caliper as necessary Refer to BASE BRAKE BLEEDING in the SERVICE PROCE DURES section in this service manual group 10 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads DISC BRAKE SHOES FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section NOTE Vehicles that are equipped with optional Four wheel di
9. 1 REAR BRAKING DISK ROTOR 2 HAT SECTION OF REAR BRAKING DISC PARKING BRAKE BRAKING SURFACE RED BRAKE WARNING LAMP The red BRAKE warning lamp is located in the instrument panel cluster and illuminates when a low brake fluid condition occurs or when the parking brake lever is applied with the ignition key in the ON position In addition the red BRAKE warning lamp illuminates when the ignition switch is moved from the OFF to the ON or CRANK position This is done to check the bulb s operation Problems with this system will generally be of the type where the warning lamp fails to turn on when it should or remains on when it should not The red BRAKE warning lamp LED is supplied with current anytime the ignition switch is ON The bulb is illuminated by completing the ground circuit using any of the following components e the brake fluid level switch located in the mas ter cylinder reservoir e the parking brake switch mounted on the park ing brake lever Fig 10 e the ignition switch when the ignition switch is first moved to the ON or CRANK position e the mechanical instrument cluster MIC with ABS e the ABS electronic brake distribution EBD The brake fluid level switch is located in the brake fluid reservoir of the master cylinder assembly Fig 1 The purpose of the switch is to provide the driver with an early warning that the brake fluid level in PL the master cylinder reservoir has dropped below an
10. 2 GROUND STRAP 3 GROUND STRAP SCREW 4 ABS SENSOR BRACKET SCREW IF EQUIPPED INSTALLATION CAUTION Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open cir cuit Be sure that cables are installed routed and clipped properly 1 Attach the wheel speed sensor to the strut using the its mounting screw Fig 20 2 Install the wheel speed sensor head in the steering knuckle Fig 19 Install the mounting bolt Tighten the mounting bolt to a torque of 12 N m 105 in Ibs 3 From the sensor bracket on the strut loop the sensor cable upward then downward at the outside of the frame rail Install the speed sensor cable grom met onto the retaining bracket attached to the brake hose on the outside of the frame rail 4 Loop the wheel speed sensor cable around the bottom of the frame rail and connect it to the wiring harness connector on the inside of the frame rail Fig 18 Remember to push in the locking tab on the connector 5 Install the tire and wheel assembly 6 Lower the vehicle 7 Road test vehicle to ensure proper operation of the base brakes and ABS PL REMOVAL AND INSTALLATION Continued WHEEL SPEED SENSOR REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING i
11. Tighten the flaring handle down once more until the tools flaring tip has firmly seated the tube to the vertical posts thus completing the flare CAUTION When inspecting the flare make sure no tubing nygal coating has been involved in the flare 9 Remove the flared tube from the flaring tool and inspect the flare to make sure it is uniform BRAKE ROTOR MACHINING NOTE Refacing the rotor is not required each time the brake pads are replaced only when the need is foreseen Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action If the rotor surface is deeply scored or warped or there is a complaint of brake roughness or brake pedal pulsation the rotor should be refaced using a hub mounted on car brake lathe Fig 33 or replaced 80b5743f Fig 33 On Car Brake Lathe 1 ON CAR BRAKE LATHE BRAKES 5 21 The use of a hub mounted on car brake lathe is highly recommended to eliminate the possibility of excessive runout It trues the brake rotor to the vehi de s hub and bearing NOTE All rotors have markings for minimum allow able thickness cast on an un machined surface of the rotor Fig 34 80aa4b6a Fig 34 Minimum Brake Rotor Thickness Markings Typical 1 ROTOR MINIMUM THICKNESS MARKING 2 ROTOR Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to CAUTION Do
12. 3 GUIDE PIN BOLTS e Remove the parking brake cable from the rear 4 HUB AND BEARING brake support plate The parking brake cable can be 5 BRAKE ROTOR removed from brake support plate using a 1 2 inch 6 RETAINER CLIP box wrench to compress the locking fingers on the 7 DUST CAP parking brake cable retainer Fig 101 8 NUT 18 To remove the rear parking brake cable from the disc brake adapter on vehides equipped with rear disc brakes e Remove the parking brake actuating lever from the parking brake cable Fig 102 PL REMOVAL AND INSTALLATION Continued Fig 99 Actuator Lever 1 PARK BRAKE ACTUATING LEVER 2 PARK BRAKE CABLE 3 BRAKE SHOE ASSEMBLIES 4 REAR SPINDLE a l Q I Fig 100 Actuating Spring 1 BRAKE SHOE ADJUSTMENT LEVER 2 ADJUSTMENT LEVER ACTUATING SPRING 3 PARK BRAKE CABLE BRAKES 5 51 9505 20 Fig 101 Parking Brake Cable Removal 1 PARK BRAKE CABLE 2 1 2 WRENCH 3 REAR BRAKE SUPPORT PLATE 4 PARK BRAKE CABLE RETAINER 80bbc3a6 Fig 102 Parking Brake Actuator Lever 1 SHOE ACTUATOR LEVER e Remove the parking brake cable from the rear disc brake adapter The parking brake cable can be removed from the disc brake adapter using a 1 2 inch offset box wrench to compress the locking fingers on the parking brake cable retainer Fig 103 19 Remove the nut then the parking brake cable routing bracket from the tension strut mounting bol
13. 4171 drive the boot into the counterbore of the caliper Fig 123 7 Install the brake shoes 8 Reinstall the caliper on the vehide and bleed the brakes as necessary Follow the installation pro cedure found in DISC BRAKE CALIPER in the REMOVAL AND INSTALLATION section in this sec tion of this service manual group CLEANING AND INSPECTION BRAKE TUBES AND HOSES Flexible rubber hose is used at both front and rear brakes Inspection of brake hoses should be per formed whenever the brake system is serviced and every 7 500 miles or 12 months whichever comes first every engine oil change Inspect hydraulic brake hoses for severe surface cracking scuffing worn spots or physical damage If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover the hose should be replaced immediately Eventual deterioration of the hose can take place with possible burst failure Faulty installation can cause twisting resulting in wheel tire or chassis interference BRAKES 5 59 9105 42 Fig 123 Installing Dust Boot In Caliper Counterbore 1 HAMMER 2 SPECIAL TOOL C 4171 3 SPECIAL TOOL C 4689 4 CALIPER The steel brake tubing should be inspected period ically for evidence of corrosion physical damage or contact with moving or hot components of the vehi de DISC BRAKES FRONT BRAKE SHOES Clean the front brake shoes and calipers with a water dampened cloth or
14. 6 Each front wheel speed sensor is attached to a boss in the steering knuckle The front tone wheel is part of the driveshaft outboard con stant velocity joint The rear wheel speed sensor is mounted to the rear disc brake adapter The rear tone wheel is an integral part of the rear wheel hub and bearing The wheel speed sensor operates on electronic energy supplied by the CAB and outputs a square wave signal whose current alternates between two constant levels Its frequency is proportional to the speed of the tone wheel The output is available as long as the sensor is powered and its state high or low corresponds to the presence or absence of tone wheel teeth The output signal is sent to the CAB If a wheel locking tendency is detected by the CAB it will then modulate hydraulic pressure via the HCU to prevent the wheel s from locking Correct ABS operation is dependent on accurate wheel speed signals The vehicle s tires and wheels all must be the same size and type to generate accu rate signals Variations in tire and wheel size can produce inaccurate wheel speed signals Improper speed sensor to tone wheel clearance can cause erratic speed sensor signals The speed sensor air gap is not adjustable but should be checked when applicable Wheel speed sensor to tone wheel clear ance specifications can be found in the SPECIFICA TIONS section within this section in this service manual group ELECTRONIC BRAKE DISTRIBUTION Veh
15. ABS operation is available at all vehide speeds above 3 5 mph If a wheel locking tendency is detected during a brake application the brake sys tem enters the ABS mode During ABS braking hydraulic pressure in the four wheel circuits is mod ulated to prevent any wheel from locking Each wheel circuit is designed with a set of electric sole noids to allow modulation although for vehicle sta bility both rear wheel solenoids receive the same electrical signal Wheel lockup may be perceived at the very end of an ABS stop and is considered nor mal During an ABS stop the brakes hydraulic system is still diagonally split However the brake system pressure is further split into four control channels During antilock operation of the vehicle s brake sys tem the wheels are controlled independently and are on separate control channels The system can build hold and release pressure at each wheel depending on signals generated by the wheel speed sensors WSS at each wheel and received at the controller antilock brake CAB 5 66 BRAKES DESCRIPTION AND OPERATION Continued NOISE AND BRAKE PEDAL FEEL During ABS braking some brake pedal movement may be felt In addition ABS braking will create ticking popping or groaning noises heard by the driver This is normal and is due to pressurized fluid being transferred between the master cylinder and the brakes If ABS operation occurs during hard braking some pulsation may be felt i
16. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston 5 Slide the outboard brake shoe onto the caliper assembly Fig 73 Be sure the retaining clip is squarely seated in the depressed areas on the caliper PL 9305 45 Fig 72 Supporting Caliper 1 FLEX HOSE 2 STRUT 3 WIRE HANGER 4 CALIPER ASSEMBLY Q 9105 62 Fig 73 Outboard Brake Shoe 1 CALIPER FINGERS 2 RETAINING CLIP PL REMOVAL AND INSTALLATION Continued 8905 14 Fig 74 Inboard Brake Shoe 1 RETAINING CLIP 2 INBOARD SHOE 6 Lubricate both adapter caliper slide abutments with a liberal amount of Mopar Multipurpose Lubri cant or an equivalent CAUTION Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter 7 Starting with the lower end carefully lower the caliper and brake shoes over the brake rotor and catch the caliper s bottom edge behind the caliper slide abutment Fig 71 Rotate the top of the caliper into mounting position on the adapter CAUTION Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed 8 Carefully install the caliper guide pin bolts Fig 70 then tighten them to a torque of 22 N m 192 in Ibs 9 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 1
17. Ko IPE nan Fig 1 Master Cylinder And ICU 1 PRIMARY BRAKE TUBE 2 MASTER CYLINDER 3 SECONDARY BRAKE TUBE 4 ABS ICU 80ae846a Fig 2 Integrated Control Unit ICU 1 HCU 2 PUMP MOTOR 3 CAB The ABS with traction control ICU consists of the following components the CAB eight build decay solenoid valves four inlet valves and four outlet valves two hydraulic shuttle valves two traction control valves valve block fluid accumulators a pump and an electric pump motor The replaceable components of the ICU are the HCU and the CAB No attempt should be made to service any components found inside of the HCU or CAB BRAKES 5 67 CONTROLLER ANTILOCK BRAKE CAB The controller antilock brake CAB is a micropro cessor based device which monitors the ABS system during normal braking and controls it when the vehi de is in an ABS stop The CAB is mounted to the bottom of the HCU Fig 2 The CAB uses a 25 way electrical connector on the vehide wiring harness The power source for the CAB is through the ignition switch in the RUN or ON position The CAB is on the PCI bus The primary fundions of the CAB are to 1 monitor the antilock brake system for proper operation 2 detect wheel locking or wheel slipping tenden cies by monitoring the speed of all four wheels of the vehicle 3 control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction cont
18. acceptable level As the fluid drops below the minimum level the fluid level switch closes and grounds the red BRAKE warning lamp circuit This turns on the red BRAKE warning lamp At this time the master cylinder fluid reservoir must be checked and filled to the full mark with DOT 3 brake fluid An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system The entire brake hydraulic system should be checked for evi dence of a leak The red BRAKE warning lamp can be turned on by the MIC in the case where the ABS is experiencing a problem where the amber ABS warning lamp needs to be illuminated and cannot The MIC will then illu minate the red BRAKE warning lamp BRAKE LAMP SWITCH The brake lamp switch is located under the instru ment panel at the brake pedal arm Fig 13 It con trols operation of the vehide s stop lamps Also if the vehicle is equipped with speed control the brake lamp switch will deactivate the speed control when the brake pedal is depressed 80bcea48 Fig 13 Brake Lamp Switch 1 SWITCH 2 CLIP 3 BRAKE PEDAL 4 CONNECTOR When the brake pedal is depressed the brake lamp switch contacts are closed completing the circuit to the stop lamps thus illuminating the stop lamps and the center high mounted stop lamp CHMSL PL DIAGNOSIS AND TESTING BASE BRAKE SYSTEM DIAGNOSIS CHARTS NOTE There are
19. adjust the parking brake shoes 1 Verify the parking brake lever is in the released position 2 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the rubber plug from the adjusting hole in the disc brake caliper adapter 4 Adjust the parking brakes Use the first bullet point for the adjustment of the left side parking brake shoes Use the second bullet point for the adjustment of the right side parking brake shoes e Insert a medium size screwdriver through adjustment hole in the left backing plate Position the screwdriver against the star wheel on the park ing brake shoe adjuster Using the screwdriver rotate the star wheel downward until a slight drag is noticed when turning the rear tire and wheel assem bly Then using the screwdriver slowly rotate the star wheel upward backing off the adjuster just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging Do not back off the adjuster star wheel more than two clicks past the point of no drag The parking brake shoe to drum clearance is now properly set e Insert a medium size screwdriver through adjustment hole in the right backing plate Position the screwdriver against the star wheel on the park ing brake shoe adjuster Using the screwdriver rotate the star wheel upward until a slight drag is noticed when turning the rear tire and wheel assem bly The
20. aluminum casting It has a machined bore to accept the master cylinder piston and also has threaded ports with seats for hydraulic brake line connections The master cylinder s primary outlet ports supply hydraulic pressure to the right front and left rear BRAKES 5 3 80bbc364 Fig 3 Non ABS Master Cylinder 1 RIGHT FRONT BRAKE TUBE 2 LEFT FRONT BRAKE TUBE 3 LEFT REAR BRAKE TUBE 4 REAR PROPORTIONING VALVES 5 RIGHT REAR BRAKE TUBE brakes while the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes Fig 3 BRAKE FLUID RESERVOIR The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required The res ervoir is made of see through plastic and it houses the brake fluid level switch BRAKE FLUID LEVEL SWITCH The brake fluid level switch is located in the brake fluid reservoir on the master cylinder Fig It senses the level of the brake fluid within the reser voir and when the level drops below an acceptable level the switch closes and completes the ground cir cuit for the red BRAKE warning lamp This turns on the red BRAKE warning lamp For additional infor mation refer to RED BRAKE WARNING LAMP also in this section PROPORTIONING VALVE NOTE Only vehicles without antilock brakes have proportioning valves Vehicles with antilock brakes have electronic brake distribution that is
21. be noticeable as light patched marks START UP CYCLE When the ignition is turned on a popping sound and a slight brake pedal movement may be noticed The ABS warning lamp will also be on for up to 5 seconds after the ignition is turned on When the vehicle is first driven off a humming may be heard or felt by the driver at approximately 20 40 kph 12 25 mph All of these conditions are a normal function of ABS as the system is performing a diag nosis check PREMATURE ABS CYCLING Symptoms of premature ABS cycling include click ing sounds from the solenoid valves pump motor running and pulsations in the brake pedal Prema PL ture ABS cycling can occur at any braking rate of the vehicle and on any type of road surface Neither the red BRAKE warning lamp nor the amber ABS warn ing lamp illuminate and no fault codes are stored in the CAB Premature ABS cycling is a condition that needs to be correctly assessed when diagnosing problems with the antilock brake system It may be necessary to use a DRB scan tool to detect and verify premature ABS cycling Check the following common causes when diagnos ing premature ABS cyding damaged tone wheels incorrect tone wheels damaged steering knuckle wheel speed sensor mounting bosses loose wheel speed sensor mounting bolts excessive tone wheel runout or an excessively large tone wheel to wheel speed sensor air gap Give special attention to these components when diagnosing a ve
22. built into the integrated control unit 5 4 BRAKES DESCRIPTION AND OPERATION Continued Proportioning valves balance front to rear braking by controlling the brake fluid hydraulic pressure to the rear brakes Under light pedal application the proportioning valve allows normal fluid flow to the rear brakes Under higher pedal effort the valve reduces fluid pressure to the rear brakes The non antilock master cylinder is a four outlet design with two screw in proportioning valves attached directly to the master cylinder housing Fig 3 One proportioning valve controls each rear brake BRAKE TUBES AND HOSES The purpose of the brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the brakes at each wheel of the vehicle The flex hoses connect the chassis brake tubes which are mounted to the vehicle s underbody to the brake at each wheel allowing for movement of the vehide s suspension The brake tubes are steel with a corrosion resistant nylon coating applied to the external surfaces The flex hoses are made of reinforced rubber DISC BRAKES FRONT The front disc brakes consist of the following com ponents Fig 4 e Brake caliper single piston floating type e Brake shoes and linings e Brake rotor HC f oti oral V UU 9505 57 Fig 4 Front Disc Brakes 1 STEERING KNUCKLE 2 BRAKE PADS AND LININGS 3 BRAKE ROTOR 4 DRIVING HUB 5 CA
23. flaring tools Do not route the tubes against sharp edges moving components or into hot areas All tubes should be attached with the recommended retaining clips PREPARING THE BRAKE TUBE FOR FLARING 1 Use Tubing Cutter Special Tool C 3478 A or an equivalent to cut off the damaged flare or tubing Fig 29 2 Make the ends of the tubing to be repaired square Fig 30 to ensure better seating of the flared end tubing 3 Ream out any burrs or rough edges showing on the inside of the tubing to be flared Fig 30 4 Strip back enough of the nylon coating at the end of the length of tubing that will flared so it will not be in the flare itself At least 5 mm should be removed NOTE Place a tube nut on the tubing before flaring it It cannot be done after the tube is flared 5 20 BRAKES SERVICE PROCEDURES Continued RH222 Fig 29 Cutting And Flaring Of Brake Fluid Tubing 9205 175 Fig 30 Brake Fluid Tube Preparation For Flaring 1 BE SURE ALL BURRS ARE REMOVED FROM INSIDE OF TUBING 2 BE SURE END OF TUBING IS SQUARE BEFORE FLARING TUBE 3 HYDRAULIC BRAKE LINE TUBING PL DOUBLE INVERTED TUBING FLARES After preparing the tubing using the procedure in PREPARING THE BRAKE TUBE FOR FLARING make a double inverted tubing flare using the follow ing procedure Fig 31 9405 5 Fig 31 Double Inverted Brake Line Tubing Flare 1 DOUBLE INVERTED STYLE FLARE CAUTION When usin
24. for twisting the brake hose during installation The flexible front hydraulic brake hose should always be installed on the vehide by first attaching the banjo fitting to the disc brake caliper Attach the hose to the brake tubing before attaching it to the front frame rail Tighten all brake line fittings to the specified torque On vehicles equipped with rear drum brakes loosely install the rear brake hose to the wheel cylin der first then bolt the intermediate routing bracket to the strut Next loosely install the hose to the steel tube coming from the master cylinder Attach the hose bracket to the body Finally tighten the tube nuts at each end of the brake hose On vehicles equipped with rear disc brakes attach the brake hose banjo fitting to the caliper first then loosely install the hose to the steel tube coming from the master cylinder Next attach the brake hose bracket to the body Finally tighten the tube nut at the each of the end of the brake hose connecting to the steel tube coming from the master cylinder BRAKES 5 33 Only double wall 4 75 mm 3 16 in steel brake line tubing with Nygal coating should be used for replacement along with its special tube nuts Care must be taken when replacing brake tubing to be sure use the proper bending and flaring tools and procedures to avoid kinking Do not route the tubes against sharp edges moving components or into hot areas All tubes should be properly attached
25. its first one inch of travel and hold it in this position Fig 13 This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir 2 Disconnect negative ground cable from the battery and isolate the cable 3 Disconned the positive cable from the battery then remove the battery from the battery tray There is one nut securing the damp on the backside of the battery holding it in place 4 Remove the one nut and one bolt securing the air deaner box in place then disconnect the wiring harness connector at the air inlet sensor 5 Lift the air cleaner box upward enough to clear its grommeted alignment post Fig 14 then move the air cleaner box forward just enough to access the battery tray mounting bolts 6 Remove the 2 bolts then the 2 nuts mounting the battery tray to its bracket Fig 14 Remove the battery tray 5 80 BRAKES REMOVAL AND INSTALLATION Continued L IK bka N DY U ate im pa 7 9505 238 Fig 13 Brake Pedal Holder 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL Fig 14 Battery Tray Mounting 1 BATTERY TRAY MOUNTING NUTS 2 BATTERY TRAY MOUNTING BOLTS 3 AIR CLEANER BOX POST 7 Disconnect the primary and secondary brake t
26. lever can be in any posi tion when releasing the automatic adjuster 16 Keeping your hands clear of the automatic adjuster sector and pawl area firmly grasp the park ing brake lever pin punch or locking pin if a new mechanism has been installed Fig 93 then quickly remove it from the parking brake lever mechanism This will allow the park brake lever mechanism to automatically adjust the parking brake cables 17 Cycle the parking brake lever once to position the parking brake cables then return the parking brake lever its released position 18 Check the rear wheels of the vehicle They should rotate freely without dragging with the lever in its released position 19 Reposition the rear carpeting into place 20 Install the rear seat cushion Be sure the seat cushion is fully installed in the retainers on the floor pan of the vehicle 21 Fully apply the parking brake lever PL REMOVAL AND INSTALLATION Continued 22 Install the center console and its mounting screws 23 Remove the blocks from the tires and wheels PARKING BRAKE SHOES REAR DISC BRAKE NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear tire and wheel assembly 3 Remove the rear disc brake caliper
27. malfunctioning 1 Bleed brakes 2 Inspect and replace drum brake components as necessary Adjust rear brakes EXCESSIVE PEDAL 1 Power brake booster runout TRAVEL PEDAL GOES TO vacuum assist FLOOR CAN T SKID WHEELS 1 Check booster vacuum hose and engine tune for adequate vacuum supply Refer to power brake booster in the diagnosis and testing section EXCESSIVE PEDAL 1 One of the two hydraulic circuits to TRAVEL ONE FRONT the front brakes is malfunctioning WHEEL LOCKS UP DURING HARD BRAKING 1 Inspect system for leaks Check master cylinder for internal malfunction PL DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES BRAKES 5 11 CORRECTION PEDAL PULSATES SURGES DURING BRAKING 1 Rear brake drum out of round or disc brake rotor has excessive thickness variation 1 Isolate condition as rear or front Reface or replace brake drums or rotors as necessary PEDAL IS SPONGY 1 Air in brake lines 2 Power brake booster runout vacuum assist 1 Bleed brakes 2 Check booster vacuum hose and engine tune for adequate vacuum supply Refer to power brake booster in the diagnosis and testing section PREMATURE REAR WHEEL LOCKUP 1 Contaminated brake shoe linings 2 Inoperative proportioning valve non ABS vehicles only 3 ABS EBD not functioning 4 Improper power brake booster assist 1 Inspect and clean or replace shoes Repair sou
28. proportioning valves screwed into the master cylinder Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled 3 Fill the brake fluid reservoir with Mopar brake fluid or an equivalent conforming to DOT 3 specifications 4 Using a wooden dowel as a pushrod Fig 28 press the pistons inward slowly applying brake pres sure then release the pressure allowing the pistons to return to the released position Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore 5 Remove the bleed tubes from the master cylin der and plug the outlet ports 6 Install the fill cap on the reservoir 7 Remove the master cylinder from the vise NOTE lt is not necessary to bleed the entire hydraulic system after replacing just the master cyl inder unless the brake system has been open to air for an excessive amount of time or air is present in the lines Only the master cylinder must be bled and filled BRAKES 5 19 8358 1 80bbc360 Fig 28 Bleeding Master Cylinder 1 WOODEN DOWEL 2 MASTER CYLINDER BRAKE TUBE REPAIR Use only double wall 4 75 mm 3 16 in steel tub ing with Nygal coating for hydraulic brake tube replacement Nygal is nylon coated galvanized steel tubing Care must be taken when repairing brake tubing to avoid kinking the tube Use the proper bending and
29. replace these items INSTALLATION 1 If the pedal has been removed from it s bracket install the pedal bushings and bolt in shaft on the bracket using the available service parts pack age 2 Install the brake pedal assembly onto the studs extending down from the instrument panel support and power brake booster Fig 40 3 Install the two nuts fastening the brake pedal bracket to the instrument panel support Fig 40 Install the nuts all the way but do not tighten them at this time PL REMOVAL AND INSTALLATION Continued 4 Install the power brake booster mounting nuts Tighten the four nuts fastening the brake pedal bracket to the power brake booster to a torque of 34 N m 300 in Ibs 5 Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 N m 300 in Ibs 6 Connect the clutch cable to the clutch pedal spacer on the pedal Fig 41 7 Connect the wiring harness connector going to the clutch pedal switches Fig 42 8 Install the power brake booster input rod on the pin mounted on the side of the brake pedal Install a new retaining clip on the end of the pin Fig 39 Do not reuse the old clip NOTE Prior to installing the brake lamp switch make sure the plunger is at it s fully extended posi tion 9 Hold the brake lamp switch firmly in one hand Then using the other hand pull outward on the plunger of the brake lamp switch until it ha
30. shoe and secure it in place with a hold down clip Fig 109 2 Install the rear brake shoe and the upper shoe return spring Fig 108 Pull the rear brake shoe over the anchor block until it is properly located on the adapter 3 Install the lower shoeto shoe return spring Fig 107 4 Install the brake shoe adjuster assembly with the star wheel towards the rear Fig 106 5 Install the rear brake shoe hold down clip Fig 105 6 Adjust the parking brake shoes to a diameter to 171 mm 6 75 inch Fig 110 7 Install the rear hub and bearing assembly on spindle 8 Install a new hub and bearing assembly retain ing nut Tighten the retaining nut to a torque of 217 N m 160 ft Ibs 9 Install the hub and bearing dust cap 10 Install the rear brake rotor 11 Install rear disc brake caliper PL 9305 41 Fig 109 Front Hold Down Clip And Brake Shoe 1 FRONT BRAKE SHOE ASSEMBLY 2 HOLD DOWN CLIP 80bbc3a8 Fig 110 Measuring Brake Shoes 1 REAR PARKING BRAKE SHOES 2 BRAKE SHOE GAUGE 12 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 13 Repeat the above procedure to the parking brake shoes on the other side of the vehicle PL REMOVAL AND INSTALLATION Continued 14 Adjust the parking brake shoes as necessary Refer to ADJ USTMENTS in this section of this ser vice manual group 15 Lower the veh
31. tabs holding the brake fluid level switch in place in the brake fluid reservoir Fig 46 3 Pull the brake fluid level switch out the other side of the reservoir INSTALLATION 1 Align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir Push the switch into the fluid reservoir until the switch retaining tabs are expanded on the other side of the reservoir locking it in place Fig 46 2 Connect the brake fluid level switch wiring connector Fig 44 POWER BRAKE BOOSTER NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Disconnect negative ground cable from the battery and isolate the cable 2 Disconnect the positive cable from the battery then remove the battery from the battery tray There is one nut securing the clamp on the backside of the battery holding it in place 3 Remove the one nut and one bolt securing the air cleaner box in place then disconnect the wiring harness connector at the air inlet sensor 4 Lift the air cleaner box upward enough to clear its grommeted alignment post Fig 48 then move the air cleaner box forward just enough to access the battery tray mounting bolts PL Fig 48 Battery Tray Mounting 1 BATTERY TRAY MOUNTING NUTS 2 BATTERY TRAY MOUNTING BOLTS 3 AIR CLEANER BOX POST
32. three diagnosis charts following that cover the RED BRAKE WARNING LAMP BRAKE NOISE and OTHER BRAKE CONDITIONS RED BRAKE WARNING LAMP CONDITION POSSIBLE CAUSES BRAKES 5 9 CORRECTION RED BRAKE WARNING LAMP ON BRAKE NOISE CONDITION 1 Parking brake lever not fully released 2 Parking brake warning lamp switch on parking brake lever 3 Brake fluid level low in reservoir 4 Brake fluid level switch 5 Mechanical instrument cluster MIC problem 6 ABS EBD malfunction POSSIBLE CAUSES 1 Release parking brake lever 2 Inspect and replace switch as necessary 3 Fill reservoir Check entire system for leaks Repair or replace as required 4 Disconnect switch wiring connector If lamp goes out replace switch 5 Refer to Chassis Diagnostic Procedures manual 6 Refer to ABS section and Chassis Diagnostic Procedures manual CORRECTION DISC BRAKE CHIRP 1 Excessive brake rotor runout 2 Lack of lubricant on brake caliper slides 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lubricate brake caliper slides DISC BRAKE RATTLE OR CLUNK 1 Broken or missing anti rattle spring clips on shoes 2 Caliper guide pins loose 1 Replace brake shoes 2 Tighten guide pins DISC BRAKE SQUEAK AT LOW SPEED WHILE APPLYING LIGHT BRAKE PEDAL EFFORT 1 Brake shoe linings 1 Replace brake shoes DRUM BRAKE CHIRP 1 Lack of lubricant o
33. to allow the retaining clip tang to pass over the end of the brake pedal pin Remove the clip PL REMOVAL AND INSTALLATION Continued 80bbc367 Fig 49 Vacuum Check Valve 1 VACUUM CHECK VALVE ON Eam Fig 50 Retaining Clip 1 BRAKE PEDAL 2 INPUT ROD 3 SCREWDRIVER 4 RETAINING CLIP 5 BRAKE PEDAL PIN BRAKES 5 31 9405 18 Fig 51 Power Brake Booster Mounting 1 POWER BRAKE BOOSTER MOUNTING NUTS 2 BRAKE PEDAL CAUTION Discard the used retaining clip it is not to be reused Replace the clip with a new one on reassembly 11 Remove the four nuts attaching the power brake booster to the instrument panel Fig 51 The nuts are accessible from under the instrument panel in the area of the brake pedal bracket 12 Slide the power brake booster forward until mounting studs clear the instrument panel Turn the booster sideways Fig 52 then remove it from the vehicle O BObbc368 Fig 52 Booster Removal installation 1 POWER BRAKE BOOSTER INSTALLATION 1 Turn the power brake booster sideways Fig 52 then install it into the engine compartment down past the heater hoses and the strut tower Rotate the booster so its four mounting studs and input rod are pointed straight toward the instrument panel Slide the input rod and studs through the instrument panel and into mounting position 2 Under the instrument panel insta
34. way connector is fully inserted in the socket of the CAB Be sure that wires are not stretched tight or pulled out of the connector 3 Verify that all the wheel speed sensor connec tions are secure 4 Look for poor mating of connector halves or ter minals not fully seated in the connector body 5 Check for improperly formed or damaged termi nals All connector terminals in a suspect circuit should be carefully reformed to increase contact tension 6 Look for poor terminal to wire connections This requires removing the terminal from the connec tor body to inspect it 7 Verify pin presence in the connector assembly 8 Check for proper ground connections Check all ground connections for signs of corrosion loose fas teners or other potential defects Refer to the wiring diagrams for ground locations 9 Look for problems with the main power sources of the vehicle Inspect the battery generator ignition circuits and other related relays and fuses If a visual check does not find the cause of the problem operate the car in an attempt to duplicate the condition and record any trouble codes Most failures of the ABS disable the ABS function for the entire ignition cycle even if the fault clears before key off There are some failure conditions however that allow ABS operation to resume during the ignition cycle in which the trouble occurred even if the trouble conditions are no longer present The following trouble con
35. 00 ft Ibs 10 Repeat the above procedure to the rear brakes on the other side of the vehide 11 Lower the vehide 12 Pump the brake pedal several times to ensure the vehide has a firm brake pedal before moving the vehicle BRAKES 5 41 13 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes BRAKE ROTOR REAR REMOVAL 1 Raise the vehide Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear tire and wheel assembly 3 Remove the rear disc brake caliper assembly from the brake rotor and store it out of the way Refer to DISC BRAKE SHOES REAR in this REMOVAL AND INSTALLATION section of this ser Vice manual group 4 Remove any clips retaining the brake rotor Fig 70 5 Remove the brake rotor by pulling it straight off the wheel mounting studs INSTALLATION NOTE Inspect the disc brake shoes and parking brake shoes before brake rotor installation 1 Install the rear brake rotor over the wheel mounting studs and onto the hub Fig 70 2 Install rear disc brake caliper Refer to DISC BRAKE SHOES REAR in this REMOVAL AND INSTALLATION section of this service manual group 3 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 4 Adjust the parking brake shoes as necessary Refer to ADJ USTMENTS in this section
36. 100 ft Ibs 4 Lower the vehicle 5 Pump the brake pedal before moving the vehi cle to set the brake shoes to the brake rotor 5 38 BRAKES REMOVAL AND INSTALLATION Continued DISC BRAKE CALIPER REAR REMOVAL 1 Using a brake pedal holding tool as shown Fig 66 depress the brake pedal past its first one inch of travel and hold it in this position This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are discon nected Ko NAN NI U NG D spot SIN VA EN 6 R 9505 238 Fig 66 Brake Pedal Holding Tool 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL 2 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the rear tire and wheel assembly 4 Remove the banjo bolt connecting the brake hose to the brake caliper Fig 67 There are two washers one on each side of the flex hose fitting that will come off with the banjo bolt Inspect and discard these if they are worn or damaged 5 Remove the two caliper guide pin bolts Fig 68 6 Remove the caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor and then lifting the caliper assembly off th
37. 14 Refer to DISASSEMBLY AND ASSEMBLY in this section of this group for the procedure on sepa rating and reattaching the CAB to the HCU INSTALLATION 1 Install the ICU onto its mounting bracket 2 Install the 3 bolts attaching the ICU to the mounting bracket Fig 17 Tighten the 3 mounting bolts to a torque of 11 N m 97 in Ibs 3 Install the four brake tubes going to the brakes into their respective outlet ports on the ICU HCU Fig 15 Using a crow foot on a torque wrench tighten the four brake tube nuts to a torque of 17 N m 145 in Ibs NOTE When installing the brake tubes from the master cylinder on the HCU the brake tube with the small tube nut is to be installed in the forward most port on the HCU with the small end going toward the master cylinder secondary port 4 Install the primary and secondary brake tubes from the master cylinder onto the HCU Fig 15 Do not completely tighten the primary and secondary tubes at this time 5 Connect the primary and secondary brake tubes to the master cylinder ports Fig 15 6 Using a crow foot on a torque wrench tighten the primary and secondary brake tube nuts at both the master cylinder and HCU to a torque of 17 N m 145 in Ibs CAUTION Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector BRAKES 5 81 7 Install the 25 way connector into the socket of the CAB as follows e Position the 25
38. 40 BRAKES REMOVAL AND INSTALLATION Continued 5 Remove the caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor and then lifting the caliper assembly off the machined abutment on the adapter Fig 71 9505 29 Fig 71 Caliper Removal installation 1 BRAKING DISC 2 CALIPER ADAPTER 3 CALIPER 4 LOWER MACHINED ADAPTER ABUTMENT 6 Hang the brake caliper from rear strut using wire or cord to prevent the weight of the caliper from damaging the brake hose Fig 72 7 Remove the outboard brake shoe from the cali per by prying the brake shoe retaining clip over the raised area on the caliper Then slide the brake shoe down and off of the brake caliper Fig 73 8 Pull the inboard brake shoe away from caliper piston until the retaining clip is free from the cavity in the piston Fig 74 9 Repeat the above procedure to the rear brakes on the other side of the vehicle INSTALLATION 1 Begin on one side of the vehicle 2 Completely retract the caliper piston back into piston bore of the caliper This is required to gain the necessary shoeto rotor clearance for the caliper installation onto the steering knuckle 3 Remove any protective paper from the noise suppression gasket on both inner and outer brake shoe assemblies if equipped 4 Install the inboard brake shoe into the caliper piston by firmly pressing the shoe in with the thumbs Fig 74
39. 5 Remove the 2 bolts then the 2 nuts mounting the battery tray to its bracket Fig 48 Remove the battery tray CAUTION The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination This can be done by pumping the brake pedal 4 5 times while the engine is not run ning until a firm brake pedal is achieved 6 Remove the master cylinder For the master cylinder without ABS removal and installation proce dure refer to MASTER CYLINDER in this section of this service manual group For the master cylinder with ABS removal and installation procedure refer to MASTER CYLINDER in the ANTILOCK BRAKE SYSTEM section of this service manual group 7 If the vehicle is equipped with ABS remove the integrated control unit ICU Refer to INTEGRATED CONTROL UNIT in REMOVAL AND INSTALLA TION within the ANTILOCK BRAKE SYSTEM sec tion of this service manual group for the procedure 8 If the vehicle is equipped with ABS remove the three bolts securing the ICU mounting bracket to the frame rail 9 Disconnect the vacuum hoses from the check valve on the power brake booster Fig 49 but do not remove the check valve from power brake booster 10 Locate the brake pedal to power brake booster input rod attachment under the instrument panel Position a small screwdriver Fig 50 under the cen ter tang of the retaining clip Rotate the screwdriver enough
40. 80a95413 Fig 23 Pump Motor To CAB Wiring Harness 1 CAB 2 PUMP MOTOR WIRING HARNESS 3 PUMP MOTOR 4 HCU VALVE BLOCK 80495414 Fig 24 CAB Attaching Bolts 1 MOUNTING BOLTS 2 CAB 3 HCU VALVE BLOCK 3 Remove the 4 bolts Fig 24 attaching the CAB to the HCU 4 Remove the CAB from the HCU Fig 25 INSTALLATION 1 Install the CAB Fig 25 on the HCU 80a95415 Fig 25 Remove Install CAB 1 CAB 2 HCU VALVES 3 HCU VALVE BLOCK 2 Install the 4 bolts mounting the CAB Fig 24 to the HCU Tighten the CAB mounting bolts to a torque of 2 N m 17 in Ibs 3 Plug the pump motor wiring harness into the CAB Fig 23 4 Install the ICU in the vehicle 5 Bleed the base and ABS hydraulic systems Refer to ANTILOCK BRAKE SYSTEM BLEEDING in this section of this service manual group 6 Road test the vehicle to ensure proper opera tion of the base brakes and ABS PL SPECIFICATIONS TONE WHEEL RUNOUT FRONT TONE WHEEL Maximum Runout 0 25 mm 0 009 in REAR TONE WHEEL Maximum Runout 0 25 mm 0 009 in WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE FRONT WHEEL Minimum Clearance 0 28 mm 0 011 in Maximum Clearance 1 42 mm 0 056 in REAR WHEEL Minimum Clearance 0 45 mm 0 018 in Maximum Clearance 1 12 mm 0 044 in BRAKES 5 85 BRAKE FASTENER TORQUE SPECIFICATIO
41. AC OFF note that no trou ble code is registered HYDRAULIC CIRCUITS AND VALVE OPERATION The hydraulic shuttle valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking The following paragraphs explain how this works For purposes of explanation only it is assumed that only the right front wheel is experiencing antilock braking the fol lowing diagrams show only the right front wheel in an antilock braking operation MK20 ABS TCS ONE CIRCUIT BRAKES 5 71 NORMAL BRAKING HYDRAULIC CIRCUIT SOLENOID VALVE AND SHUTTLE VALVE FUNCTION ABS WITH TRACTION CONTROL The hydraulic diagram Fig 7 shows a vehicle with traction control in the normal braking mode The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle The driver is applying the brake pedal this builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle The hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump motor 80989438 Fig 7 ABS With Traction Control Normal Braking Hydraulic Circuit 8 NORMALLY OPEN VALVE OFF 9 NORMALLY OPEN ASR VALVE OFF 10 FROM MASTER CYLINDER 11 HYDRAULIC SHUTTLE VALVE 12 MASTER CYLINDER PRESSURE 13 NOISE DAMPER CHAMBER 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR OFF 4 SUCTION VALVE 5 LOW PRESSURE ACCUMULATOR 6 N
42. AR PROPORTIONING VALVES RIGHT REAR BRAKE TUBE Oa BAON 6 Clean the area around where the master cylin der attaches to the power brake booster using a suit able brake cleaner such as Mopar Brake Parts Cleaner or an equivalent 7 Remove the two nuts attaching the master cyl inder to the power brake booster 8 Slide the master cylinder straight out of the power brake booster 9 To remove the proportioning valves unthread each from the master cylinder INSTALLATION NOTE The master cylinder must be bled before installing it on the vehicle 1 If removed install the proportioning valves in their master cylinder ports The valves are identical so they can be installed in either master cylinder port going to the rear brakes Make sure the O rings on the proportioning valves are new 2 Bleed the master cylinder before installing it on the vehicle Refer to MASTER CYLINDER BLEEDING in SERVICE PROCEDURES within this section of this service manual group 3 Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it s installed Do not get any cleaner or debris inside the booster PL REMOVAL AND INSTALLATION Continued 4 Position the master cylinder on the studs of the power brake booster aligning the push rod of the power brake booster with master cylinder piston push rod Carefully push the master cylinder onto the studs until it contacts the face of the boost
43. BRAKE BOOSTER PARTS IDENTIFICATION TAG 2 POWER BRAKE BOOSTER 3 BRAKE FLUID PRESSURE SWITCH 4 MASTER CYLINDER Although there is a range the preferred level is FULL If necessary adjust the brake fluid level to the FULL mark on the side of the master cylinder brake fluid reservoir BASE BRAKE BLEEDING NOTE For bleeding the ABS hydraulic system refer to ANTILOCK BRAKE SYSTEM BLEEDING in the ANTILOCK BRAKE SYSTEM section of this ser vice manual group 5 18 BRAKES SERVICE PROCEDURES Continued CAUTION Before removing the master cylinder cap wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder res ervoir CAUTION Use only Mopar brake fluid or an equiv alent from a fresh tightly sealed container Brake fluid must conform to DOT 3 specifications Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding pro cess This will only increase the amount of air in the system and make additional bleeding necessary Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system An empty reservoir will allow additional air into the brake system Check the fluid level frequently and add fluid as needed The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydrau lic system e Left rear wheel e Right front wheel e R
44. CAB are latching codes The DTC is latched and ABS braking is dis abled until the ignition switch is reset Thus ABS braking is non operational even if the original DTC has disappeared Other DTC s are non latching Any warning lamps that are turned on are only turned on as long as the DTC condition exists as soon as the condition goes away the amber ABS warning lamp is turned off although in most cases a DTC is set INTERMITTENT DIAGNOSTIC TROUBLE CODES As with virtually any electronic system intermit tent electrical problems in the ABS system may be difficult to accurately diagnose Most intermittent electrical problems are caused by faulty electrical connections or wiring A visual inspection should be done before trying to diagnose or service the antilock brake system this will eliminate unnecessary diag nosis and testing time Perform a visual inspection for loose disconnected damaged or misrouted wires or connectors include the following components and areas of the vehicle in the inspection 1 Inspect fuses in the power distribution center PDC and the wiring junction block Verify that all fuses are fully inserted into the PDC and wiring 5 76 BRAKES DIAGNOSIS AND TESTING Continued junction block A label on the underside of the PDC cover identifies the locations of the ABS fuses 2 Inspect the 25 way electrical connector at the CAB for damaged spread or backed out wiring ter minals Verify that the 25
45. EATED AROUND CALIPER BUSHING BORES 3 Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing The bushing flanges should be seated evenly on both sides of the bushing hole Fig 115 4 Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent 5 Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve Fig 116 6 Holding the convoluted boot on the opposite end of the bushing push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve Fig 116 Install the other end bushing boot into the groove on that end of the bushing sleeve 7 Verify both ends of the bushing are seated in the sleeve groves Fig 117 When the sleeve is seated properly into the bushing the sleeve bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove 9105 60 Fig 116 Installing Sleeve In Bushing 1 CALIPER 2 SLEEVE 3 BUSHING PL DISASSEMBLY AND ASSEMBLY Continued 2 BE SURE THE BUSHING IS FULLY 9205 194 Fig 117 Correctly Installed Guide Pin Sleeve And Bushing 1 CALIPER 2 BUSHING 3 SLEEVE CALIPER PISTON AND SEALS CALIPER PISTON REMOVAL WARNING UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EV
46. EFT FRONT BRAKE TUBE 3 LEFT REAR BRAKE TUBE 4 REAR PROPORTIONING VALVES 5 RIGHT REAR BRAKE TUBE Before testing the proportioning valve in question inspect the rear brake linings for contamination or for replacement shoes not meeting the OEM brake lining material specifications The proportioning valve should always be tested prior to being replaced 5 16 BRAKES DIAGNOSIS AND TESTING Continued The in line proportioning valves used on this vehi cle require special pressure fittings to test the pro portioning valves for proper proportioning valve function The pressure fittings are installed before and after the proportioning valve being tested to ver ify proportioning valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls The testing of proportioning valves for this vehicle if equipped with ABS can be found in the ANTILOCK BRAKE SYSTEM section PROPORTIONING VALVE TEST The test procedure is the same for either rear pro portioning valve After road testing the vehide to determine which wheel skids first follow the proce dure below for testing the suspect proportioning valve 1 Using a brake pedal holding tool as shown Fig 22 depress the brake pedal past its first one inch of travel and hold it in this position This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir
47. ER BE USED TO REMOVE A PIS TON FROM A CALIPER BORE PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE NOTE The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle s brake system 1 Following the removal procedure in DISC BRAKE SHOES found in this section remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehi cle so brake fluid cannot get on these components Remove the brake shoes and place a small piece of wood between the piston and caliper fingers 2 Carefully depress the brake pedal to hydrauli cally push piston out of its bore Once completed apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool This will prevent the fluid in the master cylinder reservoir from completely draining out BRAKES 5 57 3 Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle CALIPER SEAL REMOVAL CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distortion 1 To disassemble the caliper mount it in a vise equipped with protective jaws 2 Remove the piston dust boot from the caliper and discard Fig 118 PR781A Fig 118 Removing Caliper Piston Dust Boot 1 CALIPER 2 SCREWDRIVER 3 BOOT NOTE Do not use a screw driver or other meta
48. LICATIONS AND PRESSURE SPECIFICATIONS A 14 Disc Drum 300 psi Black Band 1000 psi 550 650 psi BRD 14 Disc Disc BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts Swelling indicates the presence of petroleum in the brake fluid To test for contamination put a small amount of drained brake fluid in clear glass jar If the fluid sep arates into layers there is mineral oil or other fluid contamination of the brake fluid If the brake fluid is contaminated drain and thor oughly flush the brake system Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including the master cylinder proportioning valves caliper seals wheel cylinder seals ABS hydraulic control unit and all hydraulic fluid hoses SERVICE PROCEDURES BRAKE FLUID LEVEL CHECKING Brake fluid level should be checked a minimum of twice a year Master cylinder reservoirs are marked FULL and MIN indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir Fig 25 CAUTION Use only Mopar brake fluid or an equiv alent from a tightly sealed container Brake fluid must conform to DOT 3 specifications Do not use petroleum based fluid because seal damage in the brake system will result 400 psi Bar Code Band 1000 psi 600 700 psi a Cae 2 K HL ko NOWRAY i So Q NG Fig 25 Master Cylinder 1 POWER
49. LIPER ASSEMBLY PL When the brakes are applied fluid pressure is sent to each brake caliper The pressure at the caliper is exerted equally against the caliper piston The pres sure applied to the piston is transmitted directly to the inboard brake shoe This forces the shoe lining against the inner surface of the brake rotor At the same time fluid pressure within the caliper piston bore forces the caliper to slide inward on its guide pins This action brings the outboard shoe lining into contact with the outer surface of the brake rotor This pressure on both sides of the brake rotor causes friction bringing the vehicle to a stop BRAKE CALIPER The caliper is a one piece casting with the inboard side containing a single piston cylinder bore Fig 5 The front disc brake caliper piston is manufac tured from a phenolic compound The outside diame ter of the caliper piston is 54 mm A square cut rubber piston seal is located in a machined groove in the caliper cylinder bore This provides a hydraulic seal between the piston and the cylinder wall Fig 6 The piston seal is designed to pull the piston back into the bore of the caliper when the brake pedal is released This maintains the proper brake shoe to rotor clearance A rubber dust boot is installed in the cylinder bore opening and in a groove in the piston Fig 6 This prevents contamination in the bore area The caliper is mounted to the steering knuckle using bushing
50. LY OPEN VALVE MODULATING 9 NORMALLY OPEN ASR VALVE OFF 10 FROM MASTER CYLINDER 11 HYDRAULIC SHUTTLE VALVE 12 MASTER CYLINDER PRESSURE 13 CONTROLLED WHEEL PRESSURE 14 LOW PRESSURE ACCUMULATOR PRESSURE 15 PUMP INTERSTAGE PRESSURE 16 NOISE DAMPER CHAMBER PR BRAKES 5 73 DESCRIPTION AND OPERATION Continued ABS TRACTION CONTROL HYDRAULIC CIRCUIT SOLENOID VALVE AND SHUTTLE VALVE FUNCTION ABS WITH TRACTION CONTROL The hydraulic diagram Fig 9 shows the vehicle in the traction control TC mode The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed e The normally open TC ASR valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel e The normally open TC ASR valve bypasses the pump output back to the master cylinder at a fixed pressure setting e The normally open and normally dosed valves modulate build decay the brake pressure as required to the spinning wheel MK20 ABS TCS ONE CIRCUIT ONE WHEEL ONLY TCS MODE Z PUMP PRESSURE E3 PUMP INTERSTAGE PRESSURE KJz LOW PRESSURE ACCUMULATOR PRESSURE J MASTER CYLINDER O PRESSURE ATMOSPHERIC 7 CONTROLLED WHEEL PRESSURE 8D a9i010 Fig 9 Traction Control Hydraulic Circuit 1 OUTLET VALVE 10 FROM MASTER CYLINDER 2 PUMP PISTON 11 HYDRAULIC SHUTTLE VALVE 3 PUMP MOTOR ON 12 CONTROLLED
51. ND REAR 55 CLEANING AND INSPECTION BRAKE TUBES AND HOSES 59 DISC BRAKES FRONT 59 DISC BRAKES REAR 60 DRUM BRAKES REAR 60 ADJUSTMENTS BRAKE LAMP SWITCH 2 61 DRUM BRAKE SHOES 00 61 PARKING BRAKE SHOES REAR DISC BRAKES 000 cee eee e eee eee 62 SPECIFICATIONS BRAKE FLUID 0 00 eee e eee 63 BRAKE ACTUATION SYSTEM 63 BRAKE FASTENER TORQUE SPECIFICATIONS 000 000 ee 63 SPECIAL TOOLS BASE BRAKE SYSTEM 00 64 5 2 BRAKES DESCRIPTION AND OPERATION BASE BRAKE SYSTEM OPERATION When a vehicle needs to be stopped the driver applies the brake pedal The brake pedal pushes the input rod of the power brake booster into the booster The booster uses vacuum to ease pedal effort as force is transferred through the booster to the master cyl inder The booster s output rod pushes in the master cylinder s primary and secondary pistons applying hydraulic pressure through the chassis brake tubes and proportioning valves rear only to the brakes at each tire and wheel assembly Front disc brakes control the braking of the front wheels rear braking is controlled by rear drum brakes as standard equipment Rear disc brakes and an antilock brake system ABS with traction control are optional The hydraulic brake system is diagonally split on both the non antilock and antilock braking systems This means the left front and
52. NS DESCRIPTION TORQUE BRAKE TUBES TubeNuts 17 N m 145 in Ibs MASTER CYLINDER Mounting Nuts 28 N m 250 in Ibs POWER BRAKE BOOSTER Mounting Nuts 34 N m 300 in Ibs DISC BRAKE CALIPER Caliper Banjo Bolt 48 N m 35 ft Ibs Guide Pin Bolts 22 N m 192 in Ibs Bleeder Screw 15 N m 125 in Ibs WHEEL CYLINDER REAR Mounting Bolts 13 N m 115 in Ibs Bleeder Screw 10 N m 80 in Ibs DRUM BRAKE SHOE SUPPORT PLATE REAR Mounting Bolts 75 N m 55 ft Ibs DISC BRAKE ADAPTER REAR Mounting Bolts 75 N m 55 ft Ibs HUB AND BEARING REAR Retaining Nut 217 N m 160 ft Ibs PARKING BRAKE Lever Mounting Nuts 28 N m 250 in Ibs TIRE AND WHEEL Wheel Mounting Nut 109 150 N m 80 110 ft Ibs INTEGRATED CONTROL UNIT Mounting Bolts 11 N m 97 in Ibs CAB Mounting bolts 2 N m 17 in Ibs Bracket to Frame Rail Bolts 23 Nem 200 in Ibs WHEEL SPEED SENSOR Head Mounting bolt 12 N m 105 in Ibs
53. NTENANCE group for the proper lifting procedure 2 Disconnect the wheel speed sensor cable con nector from the wiring harness on the inside of the frame rail above the front suspension crossmember Fig 18 The connector has a locking tab which that must be pulled back before the connector release tang can be depressed releasing the connection 3 Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail 4 Remove the bolt mounting the wheel speed sen sor head to the steering knuckle Fig 19 5 82 BRAKES REMOVAL AND INSTALLATION Continued Fig 18 Wiring Harness Connector 1 RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR 2 RIGHT FRONT DRIVESHAFT 3 ENGINE OIL FILTER NA LADS Q B0bce998 Fig 19 Wheel Speed Sensor 1 RIGHT FRONT WHEEL SPEED SENSOR 2 TONE WHEEL CAUTION When removing a wheel speed sensor from the knuckle do not use pliers on the sensor head This may damage the sensor head If the sen sor has seized use a hammer and a punch to tap the edge of the sensor head ear rocking the sensor side to side until free 5 Carefully remove the sensor head from the steering knuckle PL 6 Remove the screw securing the wheel speed sensor to the rear of the strut Fig 20 Remove the wheel speed sensor Fig 20 Wheel Speed Sensor At Strut 1 ABS WHEEL SPEED SENSOR ROUTING BRACKET IF EQUIPPED
54. ORMALLY CLOSED VALVE OFF 7 TO RIGHT FRONT WHEEL 5 72 ABS BRAKING HYDRAULIC CIRCUIT SOLENOID VALVE AND SHUTTLE VALVE FUNCTION ABS WITH TRACTION CONTROL The hydraulic diagram Fig 8 shows the vehicle in the ABS braking mode The diagram shows one wheel is slipping because the driver is attempting to stop the vehide at a faster rate than is allowed by the surface on which the tires are riding e The hydraulic shuttle valve closes upon brake application so that the pump motor cannot siphon brake fluid from the master cylinder MK20 ABS TCS ONE CIRCUIT ONE WHEEL ONLY ABS MODE MASTER CYLINDER BRAKES DESCRIPTION AND OPERATION Continued PL e The normally open and normally closed valves modulate build decay the brake hydraulic pressure as required e The pump motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits e The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion of the normally open valve 80a89439 Fig 8 ABS With Traction Control ABS Braking Hydraulic Circuit PRESSURE PUMP INTERSTAGE PRESSURE LOW PRESSURE ACCUMULATOR PRESSURE 9 CONTROLLED WHEEL PRESSURE 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR ON 4 SUCTION VALVE 5 LOW PRESSURE ACCUMULATOR 6 NORMALLY CLOSED VALVE MODULATING 7 TO RIGHT FRONT WHEEL 8 NORMAL
55. PL BRAKES BRAKES TABLE OF CONTENTS pa BASE BRAKE SYSTEM ge BASE BRAKE SYSTEM TABLE OF CONTENTS pa DESCRIPTION AND OPERATION BASE BRAKE SYSTEM OPERATION BASE BRAKE SYSTEM COMPONENTS DIAGNOSIS AND TESTING BASE BRAKE SYSTEM DIAGNOSIS CHARTS POWER BRAKE BOOSTER DRUM BRAKE AUTOMATIC ADJUSTER BRAKE ROTOR BRAKE DRUM PROPORTIONING VALVE BRAKE FLUID CONTAMINATION SERVICE PROCEDURES BRAKE FLUID LEVEL CHECKING BASE BRAKE BLEEDING MASTER CYLINDER BLEEDING BRAKE TUBE REPAIR BRAKE ROTOR MACHINING BRAKE DRUM MACHINING PARKING BRAKE AUTOMATIC ADJUSTER LOCK OUT REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS BRAKE PEDAL 23 ence cee ce ee eae KANA KAN AKA BRAKE LAMP SWITCH MASTER CYLINDER BRAKE FLUID RESERVOIR BRAKE FLUID LEVEL SWITCH POWER BRAKE BOOSTER PROPORTIONING VALVE BRAKES TUBES AND HOSES DISC BRAKE CALIPER FRONT DISC BRAKE SHOES FRONT ge 9 ANTILOCK BRAKE SYSTEM 005 65 page BRAKE ROTOR FRONT 37 DISC BRAKE CALIPER REAR 38 DISC BRAKE SHOES REAR 39 BRAKE ROTOR REAR 41 DRUM BRAKE WHEEL CYLINDER REAR 41 DRUM BRAKE SHOES REAR 43 BRAKE DRUM REAR 45 DRUM BRAKE SHOE SUPPORT PLATE REAR a 46 PARKING BRAKE LEVER 48 PARKING BRAKE CABLE REAR 49 PARKING BRAKE SHOES REAR DISC BRAKE 2 aaa 53 DISASSEMBLY AND ASSEMBLY DISC BRAKE CALIPER FRONT A
56. R HANDLING AND DISPOSING OF PROD UCTS CONTAINING ASBESTOS CAUTION Use only Mopar brake fluid or an equiv alent from a tightly sealed container Brake fluid must conform to DOT 3 specifications Do not use petroleum based fluid because seal damage in the brake system will result CAUTION Brake fluid will damage painted sur faces If brake fluid is spilled on any painted sur faces wash it off immediately with water CAUTION During service procedures grease or any other foreign material must be kept off the cal iper assembly surfaces of the brake rotor and external surfaces of the hub Avoid deformation scratching or nicking of the brake rotor and brake shoe linings 5 24 BRAKES REMOVAL AND INSTALLATION Continued BRAKE PEDAL NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section WITH AUTOMATIC TRANSAXLE REM OVAL 1 Disconnect and isolate the battery negative cable from its post on the battery 2 Place the steering wheel and tires in the STRAIGHT AHEAD position Using a steering wheel holder lock the steering wheel in place to keep it from rotating Fig 37 This keeps the clockspring in the proper orientation 80bc4eb5 Fig 37 Steering Wheel Holder 1 STEERING WHEEL 2 STEERING WHEEL HOLDER 3 DRIVERS SEAT 3 Remove the steering column coupling retainer pin back off the pinch bolt nut and rem
57. RETAINER CLIP 2 BRAKE ROTOR 3 HUB 4 GUIDE PIN BOLTS 5 DISC BRAKE CALIPER PL then pulling the caliper off the opposite end s caliper slide abutment on the knuckle and brake rotor INSTALLATION NOTE Step 1 below is only required when install ing a caliper after new brake shoes have been installed 1 Completely retract the caliper piston back into the bore of the caliper 2 Lubricate both steering knuckle caliper slide abutments with a liberal amount of Mopar Multi purpose Lubricant or an equivalent CAUTION Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses 3 Install the disc brake caliper with pads on the brake rotor and steering knuckle The left side cali per is installed by first sliding the top of the caliper past the top caliper slide abutment on the steering knuckle to hook the top edge of the caliper then pushing the lower end of the caliper into place against the knuckle Fig 58 The right side caliper is installed by first sliding the bottom edge of the cal iper past the lower caliper slide abutment on the steering knuckle to hook the lower edge of the cali per then pushing the top of the caliper into place against the steering knuckle 80aa4b6d Fig 58 Installing Left Caliper 1 SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT OF STEERING KNUCKLE AS SHOWN
58. SHOE TO ANCHOR SPRING 11 BRAKE ANCHOR PLATE 12 REAR BRAKE SHOE PL DISC BRAKES REAR Rear disc brakes are optional equipment on some models of this vehicle Fig 9 The rear disc brakes are similar to the front disc brakes however there are several distinctive features that require different service procedures The rear disc brakes consist of the following components e Brake caliper single piston floating type e Brake caliper adapter e Brake shoe and linings e Brake rotor drum in hat type All vehides equipped with rear disc brakes have a small duo servo drum brake mounted to the caliper adapter This is part of the parking brake system The drum brake shoes expand out against a braking surface hat section on the inside area of the disc brake rotor 80bce90f Fig 9 Rear Disc Brakes DISC BRAKE CALIPER DISC BRAKE ADAPTER GUIDE PIN BOLTS HUB AND BEARING BRAKE ROTOR RETAINER CLIP DUST CAP NUT ONoanhwWNn BRAKE CALIPER Vehicles are equipped with a caliper assembly that has a 34 mm 1 43 in piston and uses a solid non vented rotor The caliper assembly for all applications floats on rubber bushings using internal metal sleeves that are attached to the adapter using threaded guide pin bolts BRAKE CALIPER ADAPTER The brake caliper adapter and rotor shield are mounted to the rear suspension knuckles of vehicle PL DESCRIPTION AND OPERATION Continued The adapter is used to
59. SING DUST BOOT PISTON SEAL BRAKE PRESSURE ON xa RAON 13 BUSHING 14 SLEEVE 15 CALIPER GUIDE PIN BOLT 16 CAP 17 BLEEDER SCREW BRAKE ROTOR The brake shoe linings contact the brake rotor Each front brake rotor is vented to help cool it during and after brake applications It is mounted on the studs of the front wheel bearing hub DRUM BRAKES REAR Rear drum brakes are standard equipment on this vehicle The rear drum brakes consist of the major components listed in the figure Fig 7 Other com ponents related to the brake shoes themselves can be seen in the next figure Fig 8 The rear wheel drum brakes are a two shoe inter nal expanding type with an automatic adjuster screw Fig 8 The automatic adjuster screw is actuated each time the brakes are applied The automatic adjuster screw is located directly below the rear brake wheel cylinder 5 6 BRAKES DESCRIPTION AND OPERATION O ON O O BON 80bcea46 Fig 7 Rear Drum Brakes DUST CAP NUT DRUM HUB AND BEARING WHEEL CYLINDER SEAL SUPPORT PLATE BRAKE SHOES RETAINER CLIP Continued OAONOaARWDY 9 COO 1 am 2 it terre 9 D 8 D 2 9405 29 Fig 8 Drum Brake Shoes Left Side Shown WHEEL CYLINDER AUTOMATIC ADJUSTER SCREW ASSEMBLY RETURN SPRING HOLD DOWN CLIP HOLD DOWN CLIP AUTOMATIC ADJUSTER LEVER AND SPRING PARK BRAKE LEVER PARK BRAKE CABLE FRONT BRAKE SHOE 10 BRAKE
60. TIONING VALVE Material a Aluminum Function Hydraulic Pressure Proportioning BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES TubeNuts 17 N m 145 in Ibs MASTER CYLINDER Mounting Nuts 28 N m 250 in Ibs POWER BRAKE BOOSTER Mounting Nuts 34 N m 300 in Ibs DISC BRAKE CALIPER Caliper Banjo Bolt 48 N m 35 ft Ibs Guide Pin Bolts 22 N m 192 in Ibs Bleeder Screw 15 N m 125 in Ibs WHEEL CYLINDER REAR Mounting Bolts 13 N m 115 in Ibs Bleeder Screw 10 N m 80 in Ibs DRUM BRAKE SHOE SUPPORT PLATE REAR Mounting Bolts 75 N m 55 ft Ibs DISC BRAKE ADAPTER REAR Mounting Bolts 75 N m 55 ft Ibs HUB AND BEARING REAR Retaining Nut 217 N m 160 ft Ibs PARKING BRAKE Lever Mounting Nuts 28 N m 250 in Ibs TIRE AND WHEEL Wheel Mounting Nut 109 150 N m 80 110 ft Ibs INTEGRATED CONTROL UNIT Mounting Bolts 11 N m 97 in Ibs CAB Mounting bolts 2 N m 17 in Ibs Bracket to Frame Rail Bolts 23 Nem 200 in Ibs WHEEL SPEED SENSOR Head Mounting bolt 12 N m 105 in Ibs 5 64 BRAKES PL SPECIAL TOOLS BASE BRAKE SYSTEM FF KO GO NG Adapters Brake Pressure 6805 30 197 Handle Universal C 4171 2 Cj 8011d811
61. WARD 2 SELF ADJUSTER 3 OUTBOARD REAR 4 SELF ADJUSTER LEVER If the old brake shoe return or hold down springs have overheated or are damaged replace them Over heating indications are paint discoloration or dis torted end coils PL CLEANING AND INSPECTION Continued WHEEL CYLINDER With the brake drums removed inspect the wheel cylinder boots for evidence of a brake fluid leak Visually check the boots for cuts tears or heat cracks If any of these conditions exist the wheel cyl inders should be completely cleaned inspected and new parts installed If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid the brake shoes must be replaced ADJ USTMENTS BRAKE LAMP SWITCH 1 Depress and hold the brake pedal while rotat ing the brake lamp switch Fig 125 in a counter clockwise direction approximately 30 degrees 80bcea48 Fig 125 Brake Lamp Switch 1 SWITCH 2 CLIP 3 BRAKE PEDAL 4 CONNECTOR 2 Pull the switch rearward and remove it from its mounting bracket 3 If necessary disconnect the wiring harness con nector from the switch 4 Hold the brake lamp switch firmly in one hand Using the other hand pull outward on the plunger of the switch until it has ratcheted out to its fully extended position 5 If disconnected connect the wiring harness connector to the stop lamp switch BRAKES 5 61 6 Mount the brake lam
62. WHEEL PRESSURE 4 LOW PRESSURE ACCUMULATOR PRESSURE 13 SUCTION VALVE 5 LOW PRESSURE ACCUMULATOR 14 PUMP INTERSTAGE PRESSURE 6 NORMALLY CLOSED VALVE MODULATING 15 NOISE DAMPER CHAMBER 7 TO RIGHT FRONT WHEEL SPINNING 16 MASTER CYLINDER PRESSURE 8 NORMALLY OPEN VALVE MODULATING 17 PUMP PRESSURE 9 NORMALLY OPEN ASR VALVE ON REGULATING 5 74 BRAKES DIAGNOSIS AND TESTING SERVICE WARNINGS AND CAUTIONS The ABS uses an electronic control module the CAB This module is designed to withstand normal current draws associated with vehicle operation Care must be taken to avoid overloading the CAB circuits CAUTION In testing for open or short circuits do not ground or apply voltage to any of the circuits unless instructed to do so for a diagnostic proce dure CAUTION These circuits should only be tested using a high impedance multi meter or the DRB scan tool as described in this section Power should never be removed or applied to any control module with the ignition in the ON position Before removing or connecting battery cables fuses or conneciors always turn the ignition to the OFF position CAUTION Use only factory wiring harnesses Do not cut or splice wiring to the brake circuits The addition of after market electrical equipment car phone radar detector citizen band radio trailer lighting trailer brakes etc on a vehicle equipped with antilock brakes may affect the function of the ant
63. acuum check valve that is not the vacuum supply hose com ing from the intake manifold Cap off the open port on the check valve 3 Start the engine 4 Allow the engine to warm up to normal operat ing temperature and engine idle 5 Using vacuum line pliers close off the vacuum supply hose near the booster and observe the vacuum gauge If the vacuum drop exceeds 1 0 inch Hg 3 3 kPa in one minute repeat the above steps to confirm the reading The vacuum loss should be less than 1 0 inch Hg in one minute time span If the loss is more than 1 0 inch Hg replace the power brake booster If it is not continue on with this test 6 Remove the pliers from the hose temporarily 7 Apply light effort approximately 15 Ibs of force to the brake pedal and hold the pedal steady Do not move the pedal once the pressure is applied or the test results may vary 8 Have an assistant reattach the pliers to the vacuum supply hose 9 Allow 5 seconds for stabilization then observe the vacuum gauge If the vacuum drop exceeds 3 0 inches Hg 10 kPa in 15 seconds repeat the above steps to confirm the reading The vacuum loss should be less than 3 0 inches Hg in 15 seconds time span If the loss is more than 3 0 inches Hg replace the power brake booster If it is not the booster is not defective DRUM BRAKE AUTOMATIC ADJUSTER To properly test the drum brake automatic adjuster the aide of a helper inside the vehicle to apply the bra
64. ake lever handle to the released position 5 Grasp the parking brake lever output cable by hand and pull upward Continue pulling on the cable until a pin punch can be inserted through the hole in the lever mechanism sector gear and the hole in the right side of its mounting bracket Fig 93 This will lock the parking brake automatic adjustment mecha nism in place and take tension off the parking brake cables 6 Remove both rear parking brake cables from the parking brake cable equalizer Fig 94 7 Remove the rear seat cushion from the vehicle 8 Fold the rear carpeting forward to expose the parking brake cables at the end of the rear floor 9 Install the box end of a 1 2 inch wrench over the parking brake cable retainer Fig 96 Push the wrench onto the retainer until the retainer fingers are collapsed From under the carpeting grasp the parking brake cable housing and pull cable straight out of the bracket attached to the floor 10 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 11 Remove the rear tire and wheel assembly from the vehicle 12 On vehicles equipped with rear drum brakes remove the brake drum Refer to BRAKE DRUM in this section of this service manual group 13 On vehicles equipped with rear disc brakes e Remove the disc brake caliper guide pin bolts then the caliper from disc brake adapter Fig 97 e Hang the caliper out of
65. ake to the HCU accumulators and pump motor This releases decays pressure from the wheel brake thus releasing the wheel from excessive slippage Once the wheel is no longer slipping the outlet valve is closed and the inlet valve is opened to reapply build pressure There are four other valves in the HCU These four remaining valves are used for traction control Two traction control TC valves mounted in the HCU valve block are normally in the open position and close only when the traction control is applied There are also two shuttle valves which control pressure return to the master cylinder under ABS and traction control conditions These TC valves are used to isolate the rear non driving wheels of the vehicle from the hydraulic pressure that the HCU pump motor is sending to the front driving wheels when traction control is being applied The rear brakes need to be isolated from the master cylinder when traction control is being PL applied so the rear wheels do not drag For more information on the TC and shuttle valves see TRAC TION CONTROL SYSTEM in this section BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU one for the primary hydraulic circuit and one for the sec ondary hydraulic circuit Each hydraulic circuit uses a 3 cc accumulator The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle This stored fluid is used by the pump
66. all the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket e When the switch is fully seated in its bracket rotate the switch clockwise approximately 30 to lock the switch into place CAUTION Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch If too much force is used the switch or striker can be damaged 13 Gently pull back on the brake pedal until the pedal stops moving This will ratchet the switch plunger backward to the correct adjustment position 14 Install the dash to lower coupling seal in place over the lower coupling s plastic collar and dash cover 15 Verify the front tires are still STRAIGHT AHEAD position in the 5 26 BRAKES REMOVAL AND INSTALLATION Continued 16 Reconnect the steering column lower coupling to the steering column upper coupling Fig 38 Install the coupling pinch bolt an tighten the pinch bolt nut to a torque of 28 N m 250 in Ibs Install the pinch bolt retainer pin 17 Remove the steering wheel holder Fig 37 18 While looking under the instrument panel at the lower coupling rotate the steering wheel back and forth to verify that the lower coupling does not squeak against the dash to coupling seal 19 Reconnect the battery negative terminal 20 Check the stop lamps to verify they are oper ating properly and not staying on when the pedal is in the released position
67. arning lamp amber ABS warning lamp or both are turned on If it is the red BRAKE warning lamp there is a brake hydraulic problem that must be corrected before driving the vehicle Refer to the BASE BRAKE SYSTEM for diagnosis of the red BRAKE warning lamp If the red brake warning lamp is illuminated there is also a possibility that there is an ABS problem and the amber ABS warning lamp is not able to illuminate so the MIC turns on the red Brake warning lamp by default If the amber ABS warning lamp is on test drive the vehicle as described below While the amber ABS warning lamp is on the ABS is not functional The ability to stop the car using the base brake system should not be affected If a functional problem of the ABS is determined while test driving the vehicle refer to the Chassis Diagnostic Procedures manual 1 Turn the key to the OFF position and then back to the ON position Note whether the amber ABS warning lamp continues to stay on If it does refer to the diagnostic manual 2 If the amber ABS warning lamp goes out shift into gear and drive the car to a speed of 20 kph 12 mph to complete the ABS start up and drive off cycles see ABS ELECTRONIC DIAGNOSIS If at this time the amber ABS warning lamp comes on refer to the diagnostic manual 3 If the amber ABS warning lamp remains out drive the vehicle a short distance Accelerate the vehicle to a speed of at least 40 mph Bring the vehi cle to a complete st
68. as necessary Refer to BASE BRAKE BLEEDING in the SERVICE PRO CEDURES section in this service manual group 11 Road test the vehicle to make sure the brakes operate correctly DRUM BRAKE SHOES REAR NOTE Before proceeding with this removal and installation procedure review the SERVICE WARN INGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove both rear tire and wheel assemblies from the vehicle 3 Begin on one side of the vehicle 4 Remove the brake drum retaining clips if equipped Fig 78 80bcea46 Fig 78 Drum Brakes 1 DUST CAP 2 NUT 3 DRUM 4 HUB AND BEARING 5 WHEEL CYLINDER 6 SEAL 7 SUPPORT PLATE 8 BRAKE SHOES 9 RETAINER CLIP BRAKES 5 43 5 Remove the brake drum Fig 78 6 Remove the automatic adjustment lever to brake shoe spring Fig 79 80aa4b71 Fig 79 Automatic Adjustment Lever Spring 1 ADJUSTMENT LEVER 2 ADJUSTMENT LEVER TO BRAKE SHOE SPRING 3 HUB BEARING 4 LEADING BRAKE SHOE 5 AUTOMATIC ADJUSTER SCREW 7 Remove the automatic adjustment lever Fig 80 from the brake shoe Fig 80 Automatic Adjustment Lever 1 AUTOMATIC ADJUSTMENT LEVER 2 FRONT BRAKE SHOE ASSEMBLY 8 Remove the hold down clips and pins attaching the leading and trailing
69. assembly from the brake rotor and store it out of the way Refer to DISC BRAKE SHOES REAR in this REMOVAL AND INSTALLATION section of this ser vice manual group 4 Remove rear brake rotor 5 Remove the dust cap from the rear hub and bearing 6 Remove the rear hub and bearing assembly retaining nut and washer 7 Remove the rear hub and bearing assembly from the rear spindle 8 Remove the rear brake shoe assembly hold down clip Fig 105 TABI GIG MARIO 5 BZ MAN E Fig 105 Rear Brake Shoe Hold Down Clip 1 HOLD DOWN CLIP p 9305 37 BRAKES 5 53 9 Turn the brake shoe adjuster wheel until the adjuster is at shortest length 10 Remove the adjuster assembly from the park ing brake shoe assemblies Fig 106 O 9305 38 Fig 106 Parking Brake Shoe Adjuster Assembly 1 ADJUSTER 11 Remove the lower shoe to shoe spring Fig 107 9305 39 Fig 107 Brake Shoe Lower Return Spring 1 LOWER SPRING 5 54 BRAKES REMOVAL AND INSTALLATION Continued 12 Pull the rear brake shoe away from anchor Remove the rear brake shoe and upper return spring Fig 108 TU AN ms Fig 108 Brake Shoe and Upper Spring 1 UPPER SPRING 2 HOLD DOWN CLIP 3 REAR PARKING BRAKE SHOE 9305 40 13 Remove the front brake shoe hold down clip Fig 109 Remove the front brake shoe assembly INSTALLATION 1 Install the front brake
70. brake shoes to the brake support plate Fig 81 9 Remove the lower brake shoeto anchor plate return spring Fig 82 10 Remove the parking brake lever pin to brake shoe retaining clip Fig 83 5 44 BRAKES REMOVAL AND INSTALLATION Continued Fig 81 Brake Shoe Hold Down Clips And Pins 1 HOLD DOWN CLIP 2 BRAKE SHOE 3 SUPPORT PLATE 4 PIN 2 Fig 82 Brake Shoe To Anchor Plate Return Spring 1 ANCHOR PLATE 2 LOWER BRAKE SHOE RETURN SPRING 3 REAR BRAKE SHOE 4 FRONT BRAKE SHOE 5 BRAKE SUPPORT PLATE PL 9405 35 Fig 83 Parking Brake Lever Pin To Brake Shoe Retaining Clip 1 RETAINING CLIP 2 PARK BRAKE LEVER PIN 3 PARK BRAKE LEVER o Hi a ys L T UN NA NG O 80aa4b72 Fig 84 Brake Shoe Removal installation 1 UPPER RETURN SPRING 2 AUTOMATIC ADJUSTER SCREW 3 TRAILING BRAKE SHOE 4 WHEEL MOUNTING STUDS 5 LEADING BRAKE SHOE 6 BRAKE SUPPORT PLATE 11 Remove the leading and trailing brake shoes upper return spring and automatic adjuster screw from the brake support plate as an assembly Fig 84 12 Disassemble the shoes completely once on the bench 13 Repeat the above procedure to the rear brakes on the other side of the vehicle INSTALLATION 1 Begin on one side of the vehide 2 Lubricate the eight shoe contact areas on the support plate and anchor using Mopar Multi Pur pose Lubricant or equivalent Fig 85 3 Assemble t
71. cling of the build and decay valves during traction control is similar to that during antilock braking except the valves work to control wheel spin by applying the brakes whereas the ABS function is to control wheel skid by releasing the brakes HYDRAULIC SHUTTLE VALVES Two pressure relief shuttle valves allow pressure and volume to return to the master cylinder reservoir when not consumed by the build and decay valves These valves are necessary because the pump motor supplies more volume than the system requires If the brakes are applied at anytime during a trac tion control cycle the brake lamp switch triggers the control module to switch off traction control TRACTION CONTROL FUNCTION LAMP The traction control function lamp illuminates dur ing a traction control cycle displaying TRAC on the instrument panel The traction control system is enabled at each igni tion cycle It may be turned off by depressing the traction control switch button The traction control function lamp TRAC OFF illuminates immediately upon depressing the button Pressing this button again or turning off and restarting the vehicle will enable the traction control system PL DESCRIPTION AND OPERATION Continued If the CAB calculates that the brake temperatures are high the traction control system becomes inoper ative until a time out period has elapsed During this thermo protection mode the traction control func tion lamp illuminates TR
72. ditions may result in intermittent illumination of the amber ABS warning lamp e Low system voltage If Low System Voltage is detected by the CAB the CAB will turn on the ABS Warning Lamp until normal system voltage is achieved Once normal voltage is seen at the CAB normal operation resumes e High system voltage If high system voltage is detected by the CAB the CAB will turn on the Amber ABS Warning Lamp until normal system volt age is achieved Once normal voltage is again detected by the CAB normal ABS operation resumes Additional possible causes that may result in the illumination of the amber ABS warning lamp are as follows e Any condition that interrupts electrical current to the CAB may cause the amber ABS warning lamp to turn on intermittently e f PCI communication between the body control ler and the CAB is interrupted the body controller can turn on the amber ABS warning lamp PL TONE WHEEL Tone wheels can cause erratic wheel speed sensor signals Inspect tone wheels for the following possible causes e missing chipped or broken teeth contact with the wheel speed sensor wheel speed sensor to tone wheel alignment wheel speed sensor to tone wheel clearance excessive tone wheel runout tone wheel loose on its mounting surface If a front tone wheel is found to need replacement the drive shaft must be replaced No attempt should be made to replace just the tone wheel Refer to the DIFFERENTIAL AND DRIVELINE
73. e machined abutment on the adapter Fig 69 INSTALLATION NOTE Step 1 below is only required when install ing the disc brake caliper after new brake shoes have been installed PL pa Gin ej A AN Ng ki e mO NG o GB if Me Fig 67 Brake Hose Mounting 80bdbc90 1 BRAKE HOSE 2 GUIDE PIN BOLTS 3 CALIPER 4 BOLT 80bce90f Fig 68 Caliper Mounting 1 DISC BRAKE CALIPER 2 DISC BRAKE ADAPTER 3 GUIDE PIN BOLTS 4 HUB AND BEARING 5 BRAKE ROTOR 6 RETAINER CLIP 7 DUST CAP 8 NUT PL REMOVAL AND INSTALLATION Continued 9505 29 Fig 69 Removing Caliper From Adapter 1 BRAKING DISC 2 CALIPER ADAPTER 3 CALIPER 4 LOWER MACHINED ADAPTER ABUTMENT 1 Completely retract the caliper piston back into piston bore of the caliper 2 Lubricate both adapter caliper slide abutments with a liberal amount of Mopar Multipurpose L ubri cant or an equivalent CAUTION Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter 3 Starting with the lower end carefully lower the caliper and brake shoes over the brake rotor and catch the caliper s bottom edge behind the caliper slide abutment Fig 69 Rotate the top of the caliper into mounting position on the adapter CAUTION Extreme caution should be taken not to cross thread the caliper guide pin bolts wh
74. e vehicle during braking The traction control system reduces wheel slip and maintains traction at the driving speeds below 56 kph 35 mph when road conditions call for traction assistance Refer to TRACTION CONTROL SYSTEM in this section for more information Vehicles equipped with ABS use electronic brake distribution EBD to balance front to rear braking when the brakes are applied in the partial braking range Refer to ELECTRONIC BRAKE DISTRIBU TION in this section for more information There are a few performance characteristics of the Mark 20e Antilock Brake System that may at first seem abnormal but in fact are normal These char acteristics are described below BRAKES 5 65 page ANTILOCK BRAKE SYSTEM BLEEDING 77 MASTER CYLINDER BLEEDING 77 REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS 78 MASTER CYLINDER 000005 78 INTEGRATED CONTROL UNIT 79 WHEEL SPEED SENSOR FRONT 81 WHEEL SPEED SENSOR REAR 83 DISASSEMBLY AND ASSEMBLY INTEGRATED CONTROL UNIT 84 SPECIFICATIONS TONE WHEEL RUNQOUT esena diea aa iaa 85 WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE 0022 85 BRAKE FASTENER TORQUE SPECIFICATIONS ikenen easg aima daa 85 NORMAL BRAKING Under normal braking conditions the ABS func tions the same as a standard base brake system with a diagonally split master cylinder and conventional Vacuum assist ABS BRAKING
75. ease the pressure allowing the pistons to return to the released position Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore 5 Remove the bleed tubes from the master cylin der and plug the outlet ports 6 Install the fill cap on the reservoir 7 Remove the master cylinder from the vise 5 78 BRAKES SERVICE PROCEDURES Continued 8358 2 80bbc361 Fig 11 Bleeding Master Cylinder 1 WOODEN DOWEL 2 MASTER CYLINDER NOTE lt is not necessary to bleed the entire hydraulic system after replacing just the master cyl inder unless the brake system has been open to air for an excessive amount of time or air is present in the lines Only the master cylinder must be bled and filled REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS Review this entire section prior to performing any mechanical work on a vehicle equipped with ABS This section contains information on precautions per taining to potential component damage vehicle dam age and personal injury which could result when servicing an ABS equipped vehicle CAUTION Only the recommended jacking or hoist ing positions for this vehicle are to be used when ever it is necessary to lift a vehicle Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket Lifting a vehicle by the hydraulic control unit mounting bracket w
76. eases guide pin sleeve wear due to the tendency of the cal iper to follow the rotor wobble When diagnosing a brake noise or pulsation the machined disc braking surface should be checked and inspected BRAKING SURFACE INSPECTION Light braking surface scoring and wear is accept able If heavy scoring or warping is evident the rotor must be refaced or replaced Refer to SERVICE PRO CEDURES in this section of this group for informa tion on brake rotor machining Excessive wear and scoring of the rotor can cause improper lining contact on the rotor s braking sur face If the ridges on the rotor are not removed before new brake shoes are installed improper wear of the shoes will result If a vehicle has not been driven for a period of time the rotor s braking surface will rust in the areas not covered by the brake shoes at that time Once the vehicle is driven noise and chatter from the disc brakes can result when the brakes are applied PL DIAGNOSIS AND TESTING Continued Some discoloration or wear of the rotor surface is normal and does not require resurfacing when lin ings are replaced If cracks or burned spots are evi dent the rotor must be replaced ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications CAUTION Do not machine the ro
77. eed the base brake system using the stan dard pressure or manual bleeding procedure as out lined in SERVICE PROCEDURES in the BASE BRAKE SYSTEM section at the beginning of this group 5 Using the DRB select ANTILOCK BRAKES followed by MISCELLANEOUS then BLEED BRAKES Follow the instructions displayed When the scan tool displays TEST COMPLETED discon nect the scan tool and proceed 6 Bleed the base brake system a second time Check brake fluid level in the reservoir periodically to prevent emptying causing air to enter the hydrau lic system 7 Fill the master cylinder reservoir to the full level 8 Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy MASTER CYLINDER BLEEDING 1 Clamp the master cylinder in a vise 2 Attach Master Cylinder Bleed Tube Special Tool 8358 1 to the primary port of the master cylin der and tighten in place Fig 11 Attach Master Cyl inder Bleed Tube Special Tool 8358 2 to the secondary port of the master cylinder and tighten in place Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled 3 Fill the brake fluid reservoir with Mopar brake fluid or an equivalent conforming to DOT 3 specifications 4 Using a wooden dowel as a pushrod Fig 11 press the pistons inward slowly applying brake pres sure then rel
78. eeding equip ment Following the same wheel circuit sequence as pre scribed for manual bleeding 1 Attach Adapter Special Tool 6921 to the mas ter cylinder reservoir Fig 27 Fig 27 Special Tool 6921 1 MASTER CYLINDER PL SERVICE PROCEDURES Continued 2 Attach Bleeder Tank Special Tool C 3496 B or an equivalent to the adapter on the master cylinder 3 Attach a dear plastic hose to the bleeder screw and feed the hose into a dear jar containing enough fresh brake fluid to submerge the end of the hose Fig 26 4 Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid 5 After approximately 4 8 ounces of fluid have been bled through the brake circuit and an air free flow is maintained in the dear plastic hose and Jar dose the bleeder screw 6 Repeat this procedure at all the remaining bleeder screws 7 Check the brake pedal travel If pedal travel is excessive or has not been improved some air may still be trapped in the system Rebleed the brakes as necessary 8 Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct MASTER CYLINDER BLEEDING 1 Clamp the master cylinder in a vise 2 Attach four Master Cylinder Bleed Tubes Spe cial Tool 8358 1 to the four ports of the master cyl inder and tighten each in place Fig 28 The bleed tubes for the ports pertaining to the rear brakes are made to attach to the
79. em if it requires replacement the HCU must be replaced ABS FUSES The ABS fuse and the ABS pump motor fuse are located in the power distribution center PDC Refer to the sticker on the inside of the PDC cover for the location of these fuses The PDC is located on the driver s side of the engine compartment between the back of the battery and the brake master cylinder The CAB fuse can be found in the fuse junction block under the instrument panel PL DESCRIPTION AND OPERATION Continued AMBER ABS WARNING LAMP The amber ABS warning lamp is located in the instrument duster The purpose of the warning lamp is discussed in detail below When the ignition key is turned to the ON posi tion the amber ABS warning lamp is lit until the CAB completes its self tests and turns off the lamp approximately 4 seconds The amber ABS warning lamp will illuminate when the CAB detects a condi tion that results in the shutdown of ABS function The CAB sends a message to the mechanical instu ment duster MIC instructing it to turn on the amber ABS warning lamp Under most conditions when the amber ABS warn ing lamp is on only the ABS function of the brake system is affected The electronic brake distribution EBD the base brake system and the ability to stop the vehicle are not affected WHEEL SPEED SENSOR WSS At each wheel of the vehicle there is one wheel speed sensor WSS and one tone wheel Fig 3 Fig 4 Fig 5 Fig
80. en they are installed 4 Carefully install the caliper guide pin bolts Fig 68 then tighten them to a torque of 22 N m 192 in Ibs 5 Install the banjo bolt connecting the brake hose to the brake caliper Fig 67 Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting Install new wash ers if they are worn or damaged at all Thread the banjo bolt into the caliper and tighten it to a torque of 48 N m 35 ft Ibs BRAKES 5 39 6 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 7 Lower the vehide 8 Remove the brake pedal holding tool 9 Bleed the caliper as necessary Refer to BASE BRAKE BLEEDING in the SERVICE PROCE DURES section in this service manual group 10 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes DISC BRAKE SHOES REAR REMOVAL 1 Raise the vehide Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove both rear tire and wheel assemblies from vehicle 3 Begin on one side of the vehicle 4 Remove the two caliper guide pin bolts Fig 70 80bce90f Fig 70 Caliper And Rotor Mounting 1 DISC BRAKE CALIPER 2 DISC BRAKE ADAPTER 3 GUIDE PIN BOLTS 4 HUB AND BEARING 5 BRAKE ROTOR 6 RETAINER CLIP 7 DUST CAP 8 NUT 5
81. er 5 Install the two master cylinder mounting nuts and tighten each to a torque of 28 N m 250 in Ibs 6 Connect the four brake tubes to the master cyl inder and proportioning valve ports Fig 45 Tighten all tube nuts to a torque of 17 N m 145 in Ibs 7 Connect the brake fluid level switch wiring connector 8 Install the battery and clamp it in place 9 Connect the positive then the negative ground cable on the battery 10 Fill the master cylinder to the proper level 11 Road test the vehicle to ensure proper opera tion of the brakes BRAKE FLUID RESERVOIR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section NOTE The master cylinder does not need to be removed from the power brake booster for removal and installation of the brake fluid reservoir REMOVAL 1 Clean the master cylinder housing and brake fluid reservoir exterior surfaces 2 Remove the brake fluid reservoir cap Using a clean syringe or siphoning tool empty as much brake fluid as possible from the reservoir 3 Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir Fig 44 4 Remove the two plastic pins holding the reser voir to the master cylinder Fig 46 5 Lift the reservoir from the master cylinder casting 6 Remove the grommets sealing the reservoir to the mas
82. er NOTE The parking brake lever can only be in the released position when releasing the automatic adjuster 5 Keeping your hands dear of the automatic adjuster sector and pawl area firmly grasp the park ing brake lever pin punch or locking pin if a new mechanism has been installed Fig 93 then quickly remove it from the parking brake lever mechanism This will allow the park brake lever mechanism to automatically adjust the parking brake cables 6 Cycle the parking brake lever once to position the parking brake cables then return the parking brake lever its released position 7 Check the rear wheels of the vehicle They should rotate freely without dragging with the lever in its released position 8 Fully apply the parking brake lever 9 Install the center console and its mounting screws 10 Remove the blocks from the tires and wheels BRAKES 5 49 PARKING BRAKE CABLE REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section The procedure below applies to either of the two rear parking brake cables REMOVAL 1 Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released 2 Fully apply the parking brake lever then shift the transmission into neutral 3 Remove the screws attaching the center con sole then remove the center console 4 Lower the parking br
83. etaining clip over the raised area on the caliper Slide the brake shoe down and off of the caliper Fig 61 19 amp Fig 61 Removing Outboard Brake Shoe 1 CALIPER ASSEMBLY 2 HANGER WIRE 3 BRAKE FLEX HOSE 4 OUTBOARD BRAKE PAD 5 HUB BEARING ASSEMBLY 6 STEERING KNUCKLE 7 SCREWDRIVER 8 Pull the inboard brake shoe away from the cal iper piston until the retaining clip is out of the cavity in the piston Fig 62 and remove the shoe 9505 71 Fig 62 Removing Inboard Brake Shoe 1 INBOARD BRAKE SHOE 2 HANGER WIRE 3 CALIPER ASSEMBLY 4 RETAINING CLIP 5 PISTON PL 9 Repeat the above procedure to the front brakes on the other side of the vehicle INSTALLATION 1 Begin on one side of the vehicle 2 Completely retract the caliper piston back into the bore of the caliper This is required to gain the necessary shoeto rotor clearance for the caliper installation onto the steering knuckle 3 Remove any protective paper from the noise suppression gasket on both the inner and outer brake shoes if equipped 4 Install the inboard brake shoe into the caliper piston by firmly pressing the shoe in with the thumbs Fig 63 Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston 9305 119 Fig 63 Installing Inboard Brake Shoe 1 PISTON 2 BRAKE SHOE 3 CALIPER ASSEMBLY 5 Slide the new outboard brake shoe onto
84. ever use any type of a petroleum based fluid in the brake hydraulic system Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system Petroleum based fluids would be items such as engine oil transmission fluid power steering fluid etc BRAKE ACTUATION SYSTEM ACTUATION Vacuum Operated Power Brakes Standard Hydraulic System Dual Diagonally Split BRAKE PEDAL Pedal Ratio 0c eee eee 3 41 POWER BRAKE BOOSTER Make Type Bosch Vacuum Mounting Studs M8 x 1 25 Diaphragm Size Type 205 mm Tandem MASTER CYLINDER ASSEMBLY MY PGi seis it Soi a s egal Ab NG Dual Tandem Body Material Anodized Aluminum Reservoir Material Polypropelene MASTER CYLINDER BORE STROKE AND SPLIT Non ABS 22 23 mm x 34 0 mm 0 875 in x 1 34 in ABS 23 82 mm x 34 0 mm 0 937 in x 1 34 in Displacement Split 50 50 BRAKES 5 63 MASTER CYLINDER FLUID OUTLET PORTS Tube Fitting Type SAE 45 Inverted Flare W ABS Primary Tube Nut Threade ps 45 4 Ate old pain edd da 7 16 in 24 W ABS Secondary Tube Nut Thread ii ieee ead eed ws baw eas 3 8 in 24 W O ABS All Tube Nut Threads 7 16 in 24 ABS HYDRAULIC CONTROL UNIT Hydraulic Tube Fitting Type ima ga SAE 45 Inverted Flare All Tube Nut Threads 7 16 in 24 PROPOR
85. f the parking brake lever BRAKES 5 7 PARKING BRAKE CABLES There is an individual parking brake cable for each rear wheel that joins a parking cable equalizer attached to the parking brake lever to the rear park ing brakes The parking brake cables are made of flexible steel cable Both drum rear brakes and disc rear brakes use the same parking brake cable config uration but the cables are different PARKING BRAKES On vehicles equipped with rear drum brakes the rear wheel service brakes also act as the vehicle s parking brakes The rear drum brake shoes when acting as parking brakes are mechanically operated using an internal actuating lever and strut connected to the flexible steel parking brake cable The parking brakes on vehicles equipped with rear disc brakes consist of a small duo servo brake assem bly mounted to the disc brake caliper adapter Fig 11 The hat center section of the rear brake rotor serves as the braking surface drum for the parking brakes Fig 12 This parking brake application uses the same operating cable configuration as the drum brake equipped vehicles but different cables Fig 11 Parking Brake Assembly With Rear Disc Brakes 1 DISC BRAKE ADAPTER 2 PARKING BRAKE BRAKE SHOES 3 HUB BEARING ASSEMBLY 4 BRAKING DISC STONE SHIELD 5 PARKING BRAKE ACTUATING STRUT 5 8 BRAKES DESCRIPTION AND OPERATION Continued O 9205 254 Fig 12 Drum In Hat Brake Rotor
86. g brake pedal During the brake bleeding procedure be sure the brake fluid level remains dose to the FULL level in the master cylinder fluid reservoir Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required The ABS must be bled as two independent braking systems The non ABS portion of the brake system with ABS is to be bled the same as any non ABS sys tem The ABS portion of the brake system must be bled separately Use the following procedure to properly bleed the brake hydraulic system induding the ABS BLEEDING When bleeding the ABS system the following bleeding sequence must be followed to insure com plete and adequate bleeding 1 Make sure all hydraulic fluid lines are installed and properly torqued 2 Connect the DRB scan tool to the diagnostics connector The diagnostic connector is located under the lower steering column cover to the left of the steering column 3 Using the DRB check to make sure the CAB does not have any fault codes stored If it does clear them using the DRB BRAKES 5 77 WARNING WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOUR SELF AND THE PAINTED SURFACES OF THE VEHI CLE BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED 4 Bl
87. g brake tubing with Nygal coating always use flare nuts designed for this coating They have a larger hole in the center to accommodate the coating on the tube 1 Install the replacement flare nut on the tube so the threads are facing the flare yet to be made Fig 32 W 2 2 m 9405 6 Fig 32 Double Wall Inverted Flare Connection 1 INVERTED FLARE TUBE NUT 2 SEAT 3 INVERTED DOUBLE FLARE 4 TUBE 2 Open the Flaring Tool Special Tool C 4047 or an equivalent separating the tools vertical posts 3 Place the tubing in the jawed hole between the two vertical posts 4 Slowly bring the vertical posts together captur ing the tube between the halves Leave enough tub ing sticking through the top of the vertical posts to allow for flaring Apply only enough pressure to hold the tube in place PL SERVICE PROCEDURES Continued 5 Place the gauge From A over the end of the brake tube Adjust the tube height in the tool s jaws until the end of the tube contacts the recessed notch in the gauge that matches the tubing size Squeeze the hanales of the flaring tool locking the tubing in place Remove the gauge 6 Place the 3 16 inch plug gauge A down into the end of the tube Tighten the flaring handle push ing the gauge into the tube until the gauge contacts the vertical posts of the tool 7 Release the flaring handle and remove the plug gauge from the partially flared tube 8
88. gine The pedal should fall slightly then hold Less effort should be needed to apply the pedal at this time If the pedal fell as indicated perform the VACUUM LEAK TEST listed after the BASIC TEST If the pedal did not fall continue on with this BASIC TEST 3 Disconnect the vacuum hose on the side of the vacuum check valve that leads to the speed control then connect a vacuum gauge to the open vacuum port on the valve 4 Start the engine 5 When the engine is at warm operating temper ature allow it to idle and check the vacuum at the gauge 5 12 BRAKES DIAGNOSIS AND TESTING Continued If the vacuum supply is 12 inches Hg 40 5 kPa or more the power brake booster is defective and must be replaced If the vacuum supply is below 12 inches continue on with this BASIC TEST 6 Shut off the engine 7 Connect the vacuum gauge to the vacuum ref erence port on the engine intake manifold 8 Start the engine and observe the vacuum gauge If the vacuum is still low check the engine tune and repair as necessary If the vacuum is above 12 inches the hose or check to the booster has a restric tion or leak Once an adequate vacuum supply is obtained repeat the BASIC TEST VACUUM LEAK TEST 1 Disconnect the vacuum hose on the side of the power brake booster vacuum check valve that leads to the speed control then connect a vacuum gauge to the open vacuum port on the valve 2 Remove the remaining hose on the v
89. group Check the guide pin dust boots to determine if they are in good condition Replace if they are damaged dry or found to be brittle Refer to DISC BRAKE CALIPER in the DISASSEMBLY AND ASSEMBLY section in this section of this service manual group DISC BRAKES REAR BRAKE SHOES Clean the rear brake shoes and calipers with a water dampened cloth or with a brake cleaner Do not use a petroleum based product If a visual inspection does not adequately deter mine the condition of the lining a physical check will be necessary Remove the rear disc brake shoes Refer to DISC BRAKE SHOES in the REMOVAL AND INSTALLA TION section in this section of this service manual group The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly When a set of brake shoes are worn to a total thickness of approximately 7 0 mm 9 32 inch or less they should be replaced Replace both brake shoe assemblies inboard and outboard It is necessary that both front wheel sets be replaced whenever brake shoe assemblies on either side are replaced If the brake shoe assemblies do not require replacement reinstall the assemblies making sure each brake shoe is returned to the original position Refer to DISC BRAKE SHOES in the REMOVAL AND INSTALLATION section in this section of this service manual group CALIPER INSPECTION Check for brake fluid leaks in and around the boot area Check for any rupt
90. group in this service manual for removal and installation If a rear tone wheel is found to need replacement the rear hub and bearing must be replaced No attempt should be made to replace just the tone wheel Refer to the SUSPENSION group in this ser vice manual for removal and installation If wheel speed sensor to tone wheel contact is evi dent determine the cause and correct it before replacing the wheel speed sensor or tone wheel Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications Refer to SPECIFICATIONS in this section of the ser vice manual for the minimum and maximum wheel speed sensor to tone wheel clearance Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals Refer to SPECI FICATIONS in this section of the service manual for the maximum allowed tone wheel runout If tone wheel runout is excessive determine if it is caused by a defect in the driveshaft assembly or hub and bearing Replace as necessary Tone wheels are pressed onto their mounting sur faces and should not rotate independently from the mounting surface Replacement of the front drive shaft or rear hub and bearing is necessary BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts Swelling indicates the presence of petroleum in the brake fluid To test for contamination put a small amount of drained brake fluid in clear glass ja
91. he front and rear brake shoe assem bly automatic adjuster screw and upper return spring before installation on the vehicle 4 Install the preassembled brake shoes auto matic adjuster screw and upper return spring on the brake support plate Fig 84 5 Install the wave washer on the pin of park brake lever PL REMOVAL AND INSTALLATION Continued 9305 110 Fig 85 Shoe Contact Areas on Support Plate 6 Install the pin on the parking brake lever into hole in rear brake shoe assembly Fig 86 9405 37 Fig 86 Parking Brake Lever Pin Retaining Clip Installation 1 BRAKE SHOE ASSEMBLY 2 RETAINING CLIP 3 SCREWDRIVER 4 PARK BRAKE LEVER 5 PARK BRAKE LEVER PIN 7 Install both brake shoe to brake support plate hold down pins and clips Fig 81 8 Install the lower brake shoeto anchor plate return spring Fig 82 9 Install the automatic adjustment lever on the leading brake shoe Fig 80 BRAKES 5 45 10 Install the automatic adjustment lever to brake shoe spring Fig 79 11 Adjust the brake shoes out until the drum lightly drags on the shoes when it is installed Do not over adjust the brakes 12 Install the brake drum Fig 78 13 Repeat the above procedure to the rear brakes on the other side of the vehicle 14 Install the tire and wheel assemblies Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 15 Adjust the rear brake shoe
92. he studs tightening the rotor to the hub Mount the Dial Indicator Special Tool C 3339 with Mounting Adaptor Special Tool SP 1910 on steering arm The dial indicator plunger should contact braking surface of rotor approximately one inch from edge of rotor Fig 16 Check lateral runout on both sides of the rotor marking the low and high spots on both Runout limits can be found in the table at the end of this brake rotor information If runout is in excess of the specification check the lateral runout of the hub face Before removing the rotor from the hub place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken This way the original mounting spot of the rotor on the hub is indexed Fig 17 Remove the rotor from the hub NOTE Clean the hub face surface before checking runout This provides a clean surface to get an accurate indicator reading Mount Dial Indicator Special Tool C 3339 and Mounting Adaptor Special Tool SP 1910 to the steer ing knuckle Position the indicator stem so it contacts the hub face near the outer diameter Care must be taken to position stem outside of the stud circle but inside of the chamfer on the hub rim Fig 18 5 14 BRAKES CMCC PL DIAGNOSIS AND TESTING Continued 9505 110 Fig 16 Checking Rotor Runout 1 SPECIAL TOOL SP 1910 2 10 MILLIMETERS FROM EDGE 3 DISC SURFACE 4 SPECIAL TOOL C 3339 9105 44
93. hicle exhibiting premature ABS cycling After diagnosing the defective component repair or replace it as required When the component repair or replacement is completed test drive the vehicle to verify that premature ABS cyding has been cor rected ANTILOCK BRAKE SYSTEM COMPONENTS The following is a detailed description of the antilock brake system components For information on servicing base brake system components used in conjunction with these components see the BASE BRAKE SYSTEM found at the beginning of this ser vice manual group MASTER CYLINDER A vehicle equipped with ABS uses a different mas ter cylinder than a vehicle that is not equipped with ABS Vehicles equipped with ABS use a center port master cylinder with only two outlet ports Fig 1 The brake tubes from the primary and secondary outlet ports on the master cylinder go directly to the integrated control unit ICU The master cylinder mounts to the power brake booster in the same manner a non ABS master cylin der does INTEGRATED CONTROL UNIT ICU The hydraulic control unit HCU and the control ler antilock brake CAB used with this antilock brake system are combined integrated into one unit which is called the integrated control unit ICU Fig 2 The ICU is located on the driver s side of the vehicle and is mounted to the left front frame rail below the master cylinder Fig 1 PL DESCRIPTION AND OPERATION Continued KEI
94. icle DISASSEMBLY AND ASSEMBLY DISC BRAKE CALIPER FRONT AND REAR Before disassembling the brake caliper clean and inspect it Refer to CLEANING AND INSPECTION in this section of this service manual group CALIPER GUIDE PIN BUSHING REMOVAL 1 With one hand push the guide pin bushing sleeve towards the back of the caliper and at the same time pull the sleeve out the back of the caliper and bushing Fig 111 9105 57 Fig 111 Removing Sleeve From Bushing 1 CALIPER 2 SLEEVE 3 BUSHING 2 Using your fingers collapse one side of the rub ber guide pin bushing Pull the guide pin bushing out the other side of the brake caliper mounting boss Fig 112 BRAKES 5 55 9105 58 Fig 112 Removing Bushing From Caliper 1 CALIPER 2 BUSHING INSTALLATION 1 Fold the guide pin bushing in half lengthwise at the solid middle section Fig 113 Fig 113 Folded Caliper Guide Pin Bushing 1 CALIPER GUIDE PIN BUSHING NOTE To avoid damage to the bushing do not use a sharp object to install the guide pin bushing 5 56 BRAKES DISASSEMBLY AND ASSEMBLY Continued 2 Insert the folded bushing into the caliper mounting boss using your fingers Fig 114 9105 59 D Fig 114 Installing Caliper Guide Pin Bushing 1 CALIPER 2 BUSHING PL 9205 193 Fig 115 Bushing Correctly Installed In Caliper 1 BUSHING 2 CALIPER 3 BE SURE BOTH BUSHING FLANGES ARE FULLY S
95. icles equipped with ABS use electronic brake distribution EBD to balance front to rear braking 80bce999 Fig 3 Left Front Wheel Speed Sensor 1 LEFT FRONT WHEEL SPEED SENSOR 2 TONE WHEEL NG a DR 80bce998 Fig 4 Right Front Wheel Speed Sensor 1 RIGHT FRONT WHEEL SPEED SENSOR 2 TONE WHEEL The EBD is used in place of a rear proportioning valve The EBD system uses the ABS system to con trol the slip of the rear wheels in partial braking range The braking force of the rear wheels is con trolled electronically by using the inlet and outlet valves located in the integrated control unit Upon entry into EBD the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off In order to decrease the rear brake pressure the outlet valve for 5 70 BRAKES DESCRIPTION AND OPERATION Continued 2337 SL to LS a Vw Ss 80bce99a Fig 5 Left Rear Wheel Speed Sensor 1 LEFT REAR WHEEL SPEED SENSOR 2 TENSION STRUT Q A NG AE X y NG NI 80bce99 Fig 6 Right Rear Wheel Speed Sensor 1 RIGHT REAR WHEEL SPEED SENSOR 2 TENSION STRUT the rear brake circuit is pulsed This allows fluid to enter the low pressure accumulator LPA in the hydraulic control unit HCU resulting in a drop in fluid pressure to the rear brakes In order to increase the rear brake pressure the outlet valve i
96. ig 43 Brake Lamp Switch 1 SWITCH 2 CLIP 3 BRAKE PEDAL 4 CONNECTOR INSTALLATION NOTE Prior to installing brake lamp switch into bracket the plunger must be moved to its fully extended position using the procedure in Step 1 1 Hold the brake lamp switch firmly in one hand Then using the other hand pull outward on the plunger of the switch until it has ratcheted out to its fully extended position 2 Connect the wiring harness connector to the brake lamp switch 3 Mount the brake lamp switch into the bracket using the following procedure e Depress the brake pedal as far down as possible e Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket e When the switch is fully seated in its bracket rotate the switch clockwise approximately 30 to lock the switch into place Fig 43 CAUTION Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch If too much force is used the switch or striker can be damaged 5 28 BRAKES REMOVAL AND INSTALLATION Continued 4 Gently pull back on the brake pedal until the pedal stops moving This will ratchet the switch plunger backward to the correct adjustment position 5 Check the stop lamps to verify they are operat ing properly and not staying on when the pedal is in the released position MASTER CYLINDER NOTE Before proceeding with this procedure
97. ight rear wheel e Left front wheel MANUAL BLEEDING NOTE To bleed the brakes manually the aid of a helper will be required 1 Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose Fig 26 2 Have a helper pump the brake pedal three or four times and hold it in the down position 3 With the pedal in the down position open the bleeder screw at least 1 full turn 4 Once the brake pedal has dropped close the bleeder screw After the bleeder screw is closed release the brake pedal 5 Repeat the above steps until all trapped air is removed from that wheel circuit usually four or five times 6 Bleed the remaining wheel circuits in the same manner until all air is removed from the brake sys tem Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry 7 Check the brake pedal travel If pedal travel is excessive or has not been improved some air may still be trapped in the system Rebleed the brakes as necessary 8 Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct PL 9305 3 Fig 26 Proper Method for Purging Air From Brake System Typical 1 CLEAR HOSE 2 BRAKE CALIPER 3 BLEEDER SCREW 4 CLEAN BRAKE FLUID PRESSURE BLEEDING NOTE Follow pressure bleeder manufacturer s instructions for use of pressure bl
98. ill result in damage to the mounting bracket and the hydrau lic control unit CAUTION An attempt to remove or disconnect cer tain system components may result in improper system operation Only those componenis with approved removal and installation procedures in this manual should be serviced PL CAUTION Brake fluid will damage painted sur faces If brake fluid is spilled on any painted sur faces wash off with water immediately CAUTION When performing any service procedure on a vehicle equipped with ABS do not apply a 12 volt power source to the ground circuit of the pump motor in the HCU Doing this will damage the pump motor and will require replacement of the entire HCU CAUTION If welding work is to be performed on the vehicle using an electric arc welder the CAB connector should be disconnected during the weld ing operation CAUTION The CAB 25 way connector should never be connected or disconnected with the ignition switch in the ON position Many components of the ABS System are not ser viceable and must be replaced as an assembly Do not disassemble any component which is not designed to be serviced MASTER CYLINDER NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL CAUTION The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from s
99. ilock brake system ABS GENERAL DIAGNOSTICS INFORMATION This section contains information necessary to diagnose the antilock brake system Specifically this section should be used to help diagnose conditions which result in any of the following 1 amber ABS warning lamp turned on 2 brakes lock up on hard application Diagnosis of base brake conditions that are obvi ously mechanical in nature should be directed to BASE BRAKE SYSTEM at the beginning of this group Many ABS conditions judged to be a problem by the driver may be normal operating conditions See ABS OPERATION in the DESCRIPTION AND OPERATION section of this group to become famil iarized with the normal characteristics of this antilock brake system PL ABS WIRING DIAGRAM INFORMATION During the diagnosis and testing of the antilock brake system it may become necessary to reference the wiring diagrams covering the antilock brake sys tem and its components For wiring diagrams refer to GROUP 8W of this service manual It will provide you with the wiring diagrams and the circuit descrip tion and operation information covering the antilock brake system ABS VEHICLE TEST DRIVE Most ABS complaints will require a test drive to properly duplicate and diagnose the condition WARNING CONDITIONS THAT RESULT IN TURN ING ON THE RED BRAKE WARNING LAMP MAY INDICATE REDUCED BRAKING ABILITY Before test driving a brake complaint vehicle note whether the red BRAKE w
100. in contact with moving parts or an over extension of cables causing an open cir cuit Be sure that cables are installed routed and clipped properly 1 Install the wheel speed sensor head into the disc brake adapter Fig 22 2 Install the wheel speed sensor mounting bolt Tighten the mounting bolt to a torque of 12 N m 105 in Ibs 3 Install the wheel speed sensor cable routing bracket on the rear strut 4 Install wheel speed sensor cable into the rout ing dips on the rear brake hose and brake tube 5 Connect the wheel speed sensor cable connector into vehicle wiring harness Fig 21 Install the dip attaching the wheel speed sensor cable connector to vehicle s body 6 Install the tire and wheel assembly on vehicle 7 Lower the vehicle 8 Road test the vehicle to ensure proper opera tion of the base brakes and ABS 5 84 BRAKES DISASSEMBLY AND ASSEMBLY INTEGRATED CONTROL UNIT REMOVAL NOTE To replace the hydraulic control unit HCU or the controller antilock brake CAB on this vehi cle the entire integrated control unit ICU needs to be removed from the vehicle The CAB can then be separated from the HCU Do not attempt to replace the CAB with the ICU mounted in the vehicle 1 Remove the ICU from the vehicle Refer INTE GRATED CONTROL UNIT in the REMOVAL AND INSTALLATION section in this section of the service manual 2 Disconnect the pump motor wiring harness Fig 23 from the CAB
101. ing brake cables then return the parking brake lever its released position 4 Check the rear wheels of the vehicle They should rotate freely without dragging with the lever in its released position 5 Fully apply the parking brake lever BRAKES 5 23 6 Install the center console and its mounting screws 7 Remove the blocks from the tire and wheels REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS WARNING ALTHOUGH FACTORY INSTALLED BRAKE SHOE LININGS ARE MADE FROM ASBES TOS FREE MATERIALS SOME AFTERMARKET BRAKE SHOE LININGS MAY CONTAIN ASBESTOS THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE S BRAKE SYSTEM IT IS POSSIBLE THAT AFTERMARKET BRAKE SHOES MAY HAVE BEEN INSTALLED ON THE VEHICLE ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND CANCER NEVER CLEAN BRAKE COMPO NENTS BY USING COMPRESSED AIR USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST IF A VACUUM CLEANER IS NOT AVAILABLE CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS DO NOT CREATE BRAKE LINING DUST BY SANDING THE BRAKE LININGS WHEN SERVIC ING A VEHICLE DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USE ONLY SEALED AIRTIGHT BAGS OR CONTAIN ERS FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION OSHA AND THE ENVIRONMENTAL PROTECTION AGENCY EPA FO
102. is released 2 Fully apply the parking brake lever then shift the transmission into neutral 3 Remove the screws attaching the center con sole then remove the center console 4 Lower the parking brake lever handle to the released position 5 Grasp the parking brake lever output cable by hand and pull upward Continue pulling on the cable until a pin punch can be inserted through the hole in the lever mechanism sector gear and the hole in the right side of its mounting bracket Fig 36 This will lock the parking brake automatic adjustment mecha nism in place and take tension off the parking brake cables PL SERVICE PROCEDURES Continued AN K 80bbc3a1 Fig 36 Pin Punch Installed 1 PARKING BRAKE LEVER 2 PIN PUNCH 3 OUTPUT CABLE ADJUSTER UNLOADING UNLOCKING NOTE The parking brake lever can only be in the released position when releasing the automatic adjuster locking pin or pin punch 1 Be sure the rear parking brake cables are both properly installed in the equalizer 2 Keeping your hands clear of the automatic adjuster sector and pawl area firmly grasp the park ing brake lever pin punch or locking pin if a new mechanism has been installed Fig 36 then quickly remove it from the parking brake lever mechanism This will allow the park brake lever mechanism to automatically adjust the parking brake cables 3 Cycle the parking brake lever once to position the park
103. kes will be necessary PL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the access plug from the rear adjust ment slot in each brake support plate 3 Insert a thin screwdriver in the adjustment slot and push back the adjustment lever With the lever in this position back the star wheel adjustment off approximately 10 notches This will eliminate the possibility that the brake is at full adjustment and can be adjusted no further 4 Remove the screwdriver from the adjustment slot 5 Watch the star wheel through the adjustment slot while a helper applies the brake pedal As the brake shoes apply the adjustment lever should move downward turning the star wheel A definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly If the star wheel does not move as indicated the brake drum needs to be removed and further inspec tion of the rear brakes is necessary 6 If the star wheel is operating properly readjust the brakes Refer to ADJ USTMENTS in this section of this service manual group 7 Reinstall the adjustment slot access plug 8 Lower the vehicle BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back This incr
104. l tool for seal removal Using such tools can scratch the bore or leave burrs on the seal groove edges 3 Using a soft tool such as a plastic trim stick work the piston seal out of its groove in caliper pis ton bore Fig 119 Discard the old seal 4 Clean the piston bore and drilled passage ways using alcohol or a suitable solvent Wipe it dry using only a lint free doth 5 Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion can usu ally be cleared of the light scratches or corrosion using crocus cloth Bores that have deep scratches or scoring should be honed Use Caliper Hone Special Tool C 4095 or the equivalent to hone the bore Do 5 58 BRAKES DISASSEMBLY AND ASSEMBLY Continued PR782A Fig 119 Removing Piston Seal PLASTIC TRIM STICK CALIPER PISTON SEAL GROOVE PISTON SEAL BAON not over hone the bore Don not increase the diame ter of the bore more than 0 0254 mm 0 001 inch Fig 120 If the bore does not dean up within this specification a new caliper housing should be installed NOTE During the honing procedure coat the stones and bore with brake 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 honing Remove all dirt and grit by flushing the caliper bore with fresh clean brake fluid wipe it dry with a clean lint free cloth and the
105. let pressure shown in the BRAKE PROPORTIONING VALVE APPLICA TIONS AND PRESSURE SPECIFICATIONS table PL DIAGNOSIS AND TESTING Continued following this procedure If the inlet gauge pressure overshoots its target pressure when the pedal is depressed release the brake pedal relieving the pressure in the system before reapplying the pedal to reach the target pressure at the inlet gauge This is necessary to get an accurate reading of the outlet pressure 10 Once inlet pressure has been achieved check the pressure reading on the proportioning valve out let gauge If the proportioning valve outlet pressure does not agree with value shown in the table replace the proportioning valve If proportioning valve is within pressure specifications the valve is good and does not require replacement BRAKES 5 17 11 Reinstall the brake holding tool on the brake pedal and remove the test equipment from the vehicle 12 Remove the tools from the proportioning valve 13 Install the proportioning valve in the master cylinder and hand tighten until the proportioning valve is fully installed and its O ring seal is seated into the master cylinder Torque the proportioning valve to 40 N m 30 ft Ibs 14 Install the brake tube on the proportioning valve Torque the tube nut to 17 N m 145 in Ibs 15 Bleed the affected brake line See BASE BRAKE BLEEDING in this section of this service manual group BRAKE PROPORTIONING VALVE APP
106. linder 4 Binding brake pedal 1 Check for swollen seals Replace all system components containing rubber 2 Replace pins and bushings 3 Replace master cylinder 4 Replace brake pedal BRAKES DRAG REAR 1 Parking brake cables binding or ONLY froze up 2 Parking brake cable return spring not returning shoes 3 Service brakes not adjusted properly rear drum brakes only 4 Obstruction inside the center console preventing full return of the parking brake cables 1 Check cable routing Replace cables as necessary 2 Replace cables as necessary 3 Follow the procedure listed in the adjustment section 4 Remove console and remove obstruction BRAKES GRAB 1 Contaminated brake shoe linings 2 Improper power brake booster assist 1 Inspect and clean or replace shoes Repair source of contamination 2 Refer to power brake booster in the diagnosis and testing section EXCESSIVE PEDAL 1 Obstruction of brake pedal EFFORT 2 Low power brake booster assist 3 Glazed brake linings 4 Brake shoe lining transfer to brake rotor 1 Inspect remove or move obstruction 2 Refer to power brake booster in the diagnosis and testing section 3 Reface or replace brake rotors as necessary Replace brake shoes 4 Reface or replace brake rotors as necessary Replace brake shoes EXCESSIVE PEDAL 1 Air in brake lines TRAVEL VEHICLE STOPS OK 2 Rear drum brake auto adjuster
107. ll the four power brake booster mounting nuts Fig 51 Tighten the nuts to a torque of 34 N m 300 in Ibs 3 Using lubriplate or an equivalent coat the sur face of the brake pedal pin where it contacts the brake booster input rod 5 32 BRAKES REMOVAL AND INSTALLATION Continued CAUTION Use only a new brake booster input rod to brake pedal retaining clip to ensure proper retainment 4 Connect the power brake booster input rod to brake pedal pin Install a new retaining dip Do not use the old clip 5 Connect all previously removed vacuum hoses to the vacuum check valve Fig 49 6 If the vehicle is equipped with ABS install the ICU mounting bracket on the frame rail using its three bolts Tighten the nuts to a torque of 23 N m 200 in Ibs 7 If the vehicle is equipped with ABS reinstall the ICU Refer to INTEGRATED CONTROL UNIT in REMOVAL AND INSTALLATION within the ANTILOCK BRAKE SYSTEM section of this service manual group for the procedure 8 Install the master cylinder For the master cyl inder without ABS removal and installation proce dure refer to MASTER CYLINDER in this section of this service manual group For the master cylinder with ABS removal and installation procedure refer to MASTER CYLINDER in the ANTILOCK BRAKE SYSTEM section of this service manual group 9 Position the battery tray back in place Install the two bolts then the two nuts mounting the bat tery tray to its bracke
108. ly when the solenoid valves are checked DRIVE OFF CYCLE The first time the vehicle is set in motion after an ignition off on cycle the drive off cycle occurs This cyde is performed when the vehide reaches a speed of approximately 20 kph 12 mph BRAKES 5 75 e The pump motor is briefly activated to verify function When the pump motor is briefly activated a whirling or buzzing sound may be heard by the driver This sound is normal indicating the pump motor is running e The wheel speed sensor output correct operating range is verified ONGOING TESTS While the system is operating these tests are per formed on a continuous basis e solenoid continuity e wheel speed sensor continuity e wheel speed sensor output DIAGNOSTIC TROUBLE CODES DTC s Diagnostic trouble codes DTC s are kept in the controller s memory until either erased by the techni cian using the DRB or erased automatically after 3500 miles or 255 ignition key cycles whichever occurs first DTC s are retained by the controller even if the ignition is turned off or the battery is dis connected More than one DTC can be stored at a time When accessed the number of occurrences ignition key cycles and the DTC that is stored are displayed Most functions of the CAB and the ABS system can be accessed by the technician for testing and diagnostic purposes using the DRB LATCHING VERSUS NON LATCHING DIAGNOSTIC TROUBLE CODES Some DTC s detected by the
109. matic adjustment mecha nism in place and take tension off the parking brake cables 6 Remove both rear parking brake cables from the parking brake cable equalizer Fig 94 7 Remove the wiring harness electrical connector from the parking brake warning lamp switch on the parking brake lever Fig 95 8 Remove the two nuts attaching the parking brake lever to the vehicle Fig 95 9 Remove the parking brake lever from the vehi de PL TA o jm 80bbc3a1 Fig 93 Pin Punch Installed 1 PARKING BRAKE LEVER 2 PIN PUNCH 3 OUTPUT CABLE 80bbe3a2 Fig 94 Parking Brake Cables At Equalizer 1 LEVER OUTPUT CABLE 2 EQUALIZER 3 REAR PARKING BRAKE CABLES PL REMOVAL AND INSTALLATION Continued 80bbc3b5 Fig 95 Parking Brake Lever 1 MOUNTING NUTS 2 PARKING BRAKE LEVER 3 PARKING BRAKE WARNING LAMP SWITCH CONNECTOR INSTALLATION 1 Place the parking brake lever on the mounting studs on the vehicle floor Install and tighten the two mounting nuts to a torque of 28 N m 250 in Ibs Fig 95 2 Connect the wiring harness electrical connector on the parking brake warning lamp switch Fig 95 3 Install both rear park brake cables into the equalizer on the parking brake lever output cable Fig 94 4 Ensure that the parking brake cables are cor rectly installed on the equalizer and aligned with the cable track on the parking brake lev
110. motor to provide build pressure for the brake hydrau lic system When the antilock stop is complete the accumulators are drained by the pump motor There are two noise dampening chambers in the HCU on this vehicle equipped with traction control PUMP MOTOR There are two pump assemblies in the HCU one for the primary hydraulic circuit and one for the sec ondary hydraulic circuit Both pumps are driven by a common electric motor Fig 2 This DC type motor is integral to the HCU and is controlled by the CAB The pump motor provides the extra amount of brake fluid needed during antilock braking Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop The pump mechanism consists of two opposing pistons operated by an eccentric camshaft In operation these pistons are used to purge fluid from the accumulators back into the master cylinder circuits When the antilock stop is complete the pump motor drains the accumu lators The pump motor is also used to build pressure when the system goes into traction control mode F or more information refer to TRACTION CONTROL SYSTEM in this section The CAB may turn on the pump motor when an antilock stop is detected The pump motor continues to run during the antilock stop and is turned off after the stop is complete Under some conditions the pump motor runs to drain the accumulators during the next drive off The pump motor is not a serviceable it
111. mount the brake caliper to the vehicle Fig 9 The adapter has two machined abut ments which are used to position and align the cal iper and brake pads for movement inboard and outboard The adapter also mounts the parking brake shoes and actuating cables to the vehicle PARKING BRAKES The parking brakes Fig 4 consist of the following components e Hand operated park brake lever automaticad justing e Parking brake cables e Actuation levers and struts e Duo servo parking brake assembly rear disc only PARKING BRAKE LEVER All vehicles are equipped with a center mounted hand operated parking brake lever mounted between the front seats Fig 10 This lever is an automatic adjusting type that continuously applies minimal tension to the parking brake cables to keep them in adjustment at all times Due to this feature the parking brake cable system does not require adjust ment Proper parking brake system adjustment is obtained by proper drum brake or drum in hat brake shoe adjustment When service is needed the lever auto adjust mechanism must be reloaded and locked out before service can be performed 80bb 3a3 Fig 10 Parking Brake Lever 1 PARKING BRAKE LEVER 2 PARKING BRAKE WARNING LAMP SWITCH 3 OUTPUT CABLE The parking brake lever has a short output cable with an equalizer bracket attached to it that connects to the parking brake cables Fig 10 The output cable can only be serviced as part o
112. n using the screwdriver slowly rotate the star wheel downward backing off the adjuster just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging Do not back off the adjuster star wheel more that two clicks past the point of no drag The parking brake shoe to drum clearance is now properly set 5 Install the rubber plug in the adjusting holes of the disc brake caliper adapter 6 Lower the vehicle until the rear tires are just clearing the floor 7 Reach inside the vehicle and fully apply and release the park brakes two times after adjusting the parking brake shoes 8 With the parking brake lever in the fully applied position attempt to hand rotate each rear tire and wheel assembly to ensure that the parking brake shoes are working 9 With the parking brake lever in the released position hand rotate each rear tire and wheel assem bly to ensure that the parking brake shoes are not dragging PL SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehide must conform to DOT 3 specifications and SAE J 1703 standards No other type of brake fluid is recommended or approved for usage in the vehicle brake system Use only Mopar brake fluid or an equivalent from a tightly sealed container CAUTION Never use reclaimed brake fluid or fluid from an container which has been left open An open container will absorb moisture from the air and contaminate the fluid CAUTION N
113. n brake support plate be sure it is positioned squarely hor izontal to the brake support plate 2 Install the wheel cylinder onto brake support plate Tighten the attaching bolts to a torque of 13 N m 115 in Ibs 3 Install the brake support plate and gasket on rear suspension knuckle Tighten the support plate mounting bolts to a torque of 75 N m 55 ft Ibs 4 Insert the parking brake cable into its mount ing hole in the brake support plate Push the cable housing in until the retainer s fingers lock into place 5 Hand start the brake flex hose tube fitting to the wheel cylinder Tighten the tube nut to a torque of 17 N m 145 in Ibs 6 Attach the parking brake cable to the parking brake actuator 7 Install the rear brake shoe assemblies on the brake support plate 8 Install the rear hub and bearing assembly on the spindle Install a new hub and bearing retaining nut Fig 91 Tighten the retaining nut to a torque of 217 N m 160 ft Ibs Install dust cap 9 Install the brake drum 10 Install the wheel and tire assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 11 Adjust the rear brake shoes Refer to ADJ USTMENTS in this section of this service man ual group 12 Lower the vehicle 13 Remove the brake pedal holding tool 14 Bleed the wheel cylinder as necessary Refer to BASE BRAKE BLEEDING in the SERVICE PRO CEDURES section in this service manual group
114. n brake shoe support plate where shoes ride 2 Wheel cylinder out of alignment 1 Lubricate shoe contact areas on brake shoe support plates 2 Loosen wheel cylinder mounting bolts realign wheel cylinder with brake shoes and tighten mounting bolts DRUM BRAKE CLUNK 1 Drum s have threaded machined braking surface 1 Reface or replace drake drums as necessary DRUM BRAKE HOWL OR MOAN 1 Lack of lubricant on brake shoe support plate where shoes ride and at the anchor 2 Rear brake shoes 1 Lubricate shoe contact areas on brake shoe support plates and at the anchor 2 Replace rear brake shoes DRUM BRAKE SCRAPING OR WHIRRING 1 ABS wheel speed sensor or tone wheel 1 Inspect correct or replace faulty component s SCRAPING METAL TO METAL 1 Foreign object interference with brakes 2 Brake shoes worn out 1 Inspect brakes and remove foreign object 2 Replace brake shoes Inspect rotors and drums Reface or replace as necessary 5 10 BRAKES DIAGNOSIS AND TESTING Continued OTHER BRAKE CONDITIONS CONDITION POSSIBLE CAUSES PL CORRECTION BRAKES CHATTER 1 Rear brake drum out of round or disc brake rotor has excessive thickness variation 1 Isolate condition as rear or front Reface or replace brake drums or rotors as necessary BRAKES DRAG FRONT OR 1 Contaminated brake fluid ALL 2 Binding caliper pins or bushings 3 Binding master cy
115. n clean it a second time 6 Inspect the caliper piston for pitting scratches or any physical damage Replace the piston if there is evidence of scratches pitting or physical damage CALIPER SEAL AND PISTON INSTALLATION NOTE Never use an old piston seal 1 Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore The seal should be started at one area of the groove and gently worked around and into the groove Fig 121 using only your clean fingers to seat it 2 Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot PL 9105 41 Fig 120 Honing Brake Caliper Piston Bore 1 CALIPER 2 CALIPER BORE 3 SPECIAL TOOL C 4095 Fig 121 Installing New Piston Seal 1 CALIPER 2 PISTON SEAL 3 SEAL GROOVE 3 Position the dust boot over the piston after coating it with brake fluid CAUTION Force applied to the piston to seat it in the bore must be applied uniformly to avoid cock ing and binding of the piston PL DISASSEMBLY AND ASSEMBLY Continued 4 Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore Fig 122 Fig 122 Installing Piston Into Caliper Bore 1 BOOT 2 PISTON 3 CALIPER 5 Position the dust boot into the counterbore of the caliper assembly piston bore 6 Using a hammer and Installer Special Tool C 4689 and Handle Special Tool C
116. n the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the tire and wheel assembly from the vehicle 3 Disconnect the wheel speed sensor cable con nector from the vehicle wiring harness Fig 21 Remove the clip attaching wheel speed sensor cable connector to the vehicle s body 80bbc3b4 Fig 21 Wheel Speed Sensor Connector 1 FUEL TANK 2 TENSION STRUT 3 WHEEL SPEED SENSOR CONNECTOR 4 LOCKING TAB 5 CLIP 4 Remove the wheel speed sensor cable routing bracket from under rear brake flex hose mounting bracket Then remove the speed sensor cable from the routing dips on the rear brake flex hose and chassis brake tube 5 Remove the bolt attaching the wheel speed sen sor cable routing bracket to rear strut CAUTION When removing a wheel speed sensor from the rear disc brake adapter do not use pliers on the sensor head This may damage the sensor head If the sensor has seized use a hammer and a BRAKES 5 83 punch to tap the edge of the sensor head ear rock ing the sensor side to side until free 6 Remove the bolt attaching the wheel speed sen sor to the rear disc brake adapter Fig 22 then carefully remove the sensor head from the rear disc brake adapter and vehide NG 80bce99 Fig 22 Rear Wheel Speed Sensor 1 RIGHT REAR WHEEL SPEED SENSOR 2 TENSION STRUT INSTALLATION CAUTION Failure to install speed sensor cables properly may result
117. n the vehicle body due to fore and aft movement of the suspension as brake pressures are modulated At the end of an ABS stop ABS is turned off when the vehicle is slowed to a speed of 3 4 mph There may be a slight brake pedal drop anytime that the ABS is deactivated such as at the end of the stop when the vehicle speed is less than 3 mph or during an ABS stop where ABS is no longer required These conditions exist when a vehicle is being stopped on a road surface with patches of ice loose gravel or sand on it Also stopping a vehicle on a bumpy road sur face activates ABS because of the wheel hop caused by the bumps TIRE NOISE AND MARKS Although the ABS system prevents complete wheel lockup some wheel slip is desired in order to achieve optimum braking performance Wheel slip is defined as follows O percent slip means the wheel is rolling freely and 100 percent slip means the wheel is fully locked During brake pressure modulation wheel slip is allowed to reach up to 25 30 percent This means that the wheel rolling velocity is 25 30 percent less than that of a free rolling wheel at a given vehicle speed This slip may result in some tire chirping depending on the road surface This sound should not be interpreted as total wheel lockup Complete wheel lockup normally leaves black tire marks on dry pavement The ABS will not leave dark black tire marks since the wheel never reaches a fully locked condition However tire marks may
118. not machine the rotor if it will cause the rotor to fall below minimum thickness Before installation verify the brake rotor face and the hub adapters are free of any chips rust or con tamination When mounting and using the brake lathe strict attention to the brake lathe manufacturer s operating instructions is required Machine both sides of the brake rotor at the same time Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut SPECIFICATIONS AND LIMITS When refacing a rotor the required TIR Total Indicator Reading and thickness variation limits MUST BE MAINTAINED Extreme care in the oper ation of rotor turning equipment is required 5 22 BRAKES SERVICE PROCEDURES Continued PL BRAKE ROTOR LIMITS Minimum Rotor Thickness Rotor Thickness Braking Rotor Front Rotor 21 87 22 13 mm 0 861 0 871 in Rotor Micro Finish Rotor Thickness Variation Rotor Run Out 20 4 mm 0 013 mm 0 08 mm 0 803 in 0 0005 in 0 003 in MSi RMS 8 75 9 25 mm 7 25 mm 0 013 mm 0 08 mm 0 344 0 364 in 0 285 in 0 0005 in 0 003 in 1680 RMS TIR Total Indicator Reading Measured On Vehicle BRAKE DRUM MACHINING If a brake drum is deeply scored or warped it can be machined on a brake lathe equipped to machine brake drums Follow the manufacturers instructions on the machining procedure Measure the brake drum diameter before machin ing If machining the drum will cause the dr
119. nout Brake drum runout should be checked with the drum mounted on a brake lathe Brake drum runout should not exceed 0 1524 mm 0 006 inch If either of these measurements are not within specification reface or replace the drum Refer to BRAKE DRUM MACHINING in the SERVICE PRO CEDURES section of this service manual group for refacing procedures Always replace the drum if machining will cause the diameter to exceed drum maximum diameter All brake drums are marked with the maximum allow able brake drum diameter Fig 20 80aa4b6b Fig 20 Brake Drum Maximum Diameter Identification 1 HUB BEARING ASSEMBLY 2 WHEEL MOUNTING STUDS 3 BRAKE DRUM MAXIMUM DIAMETER MARKING 4 REAR BRAKE DRUM Rotor Micro Finish Rotor Thickness Variation Rotor Runout 20 4 mm 0 013 mm 0 13 mm 0 803 in 0 0005 in 0 005 in isons Bear Rotor 8 75 9 25 mm 7 25 mm 0 344 0 364 in 0 285 in 0 013 mm 0 0005 in 0 13 mm 0 005 in 15 80 RMS PROPORTIONING VALVE If premature rear wheel skid occurs on a hard brake application it could be an indication that a malfunction has occurred with one of the proportion ing valves One proportioning valve controls the right rear brake and the other proportioning valve controls the left rear brake Fig 21 Therefore a road test to determine which rear brake skids first is essential 80bbc364 Fig 21 Proportioning Valve Location RIGHT FRONT BRAKE TUBE 1 2 L
120. nstall the parking brake shoes actuator lever on the parking brake cable Fig 102 e Install the parking brake shoe assemblies on the disc brake adapter Fig 98 6 Install the hub and bearing on the rear spin dle Install a new hub and bearing retaining nut Tighten the retaining nut to a torque of 217 N m 160 ft Ibs 7 Install the hub and bearing dust cap 8 On drum brake equipped vehicles install the rear brake drum 9 On vehicles equipped with rear disc brakes install the brake rotor then the disc brake caliper Fig 97 Install the two caliper guide pin bolts then tighten them to a torque of 22 N m 192 in Ibs 10 Install the rear tire and wheel assembly Tighten all wheel nuts to a torque of 135 N m 100 ft Ibs 11 Lower the vehicle 12 Ensure that the seal grommet on the cable that was installed from underneath is fully seated into the floor pan 13 Route the parking brake cable under the car peting up to parking brake cable retaining bracket on floor pan Install the parking brake cable through the retaining bracket Push the cable in until the locking fingers on the cable retainer lock the cable into place 14 Install the rear parking brake cables into the equalizer on the parking brake lever output cable Fig 94 15 Ensure that the parking brake cables are cor rectly installed on the equalizer and aligned with the cable track on the parking brake lever NOTE The parking brake
121. nstalling it on the vehide Refer to MASTER CYLINDER BLEEDING in SERVICE PROCEDURES within this section of this service manual group 2 Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it s installed Do not get any cleaner or debris inside the booster BRAKES 5 79 3 Position the master cylinder on the studs of power brake vacuum booster aligning the booster push rod with the master cylinder push rod Care fully push the master cylinder onto the studs until it contacts the face of the booster 4 Install the two master cylinder mounting nuts Fig 12 Tighten the mounting nuts to a torque of 28 N m 250 in Ibs 5 Connect the primary and secondary brake tubes to the master cylinder primary and secondary ports Fig 12 Tighten the nuts to a torque of 17 N m 145 in Ibs 6 Install the wiring harness connector on the master cylinder reservoir fluid level switch 7 Install the battery and clamp in place 8 Connect the positive then the negative ground cable on the battery 9 Fill the master cylinder to the proper fill level 10 Road test the vehicle to ensure proper opera tion of the base and antilock brake systems INTEGRATED CONTROL UNIT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Using a brake pedal holder depress the brake pedal past
122. occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3 500 miles of vehicle operation 5 68 BRAKES DESCRIPTION AND OPERATION Continued CONTROLLER ANTILOCK BRAKE INPUTS e wheel speed sensors four stop lamp switch ignition switch system relay voltage ground traction control lamp diagnostic communication PCI CONTROLLER ANTILOCK BRAKE OUTPUTS e amber ABS warning lamp actuation through MIC e red BRAKE warning lamp actuation through MIC e traction control lamp actuation through MIC e diagnostic communication PCI HYDRAULIC CONTROL UNIT HCU The hydraulic control unit HCU is mounted to the CAB as part of the ICU Fig 2 The HCU con trols the flow of brake fluid to the brakes using a series of valves and accumulators A pump motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves The inlet valves are spring loaded in the open position and the outlet valves are spring loaded in the closed position during normal braking The fluid is allowed to flow from the master cylinder to the whee brakes During an ABS stop these valves cycle to maintain the proper slip ratio for each wheel The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel br
123. of this ser vice manual group 5 Lower the vehicle 6 Pump the brake pedal before moving the vehi cle to set the brake shoes to the brake rotor DRUM BRAKE WHEEL CYLINDER REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section 5 42 BRAKES REMOVAL AND INSTALLATION Continued REMOVAL 1 Using a brake pedal holder depress the brake pedal past its first one inch of travel and hold it in this position Fig 75 This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir ATON li A np U La ae e to Hr 9505 238 Fig 75 Brake Pedal Holder 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL 2 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the rear tire and wheel assembly 4 Disconnect the rear brake flex hose from the wheel cylinder Fig 76 5 Remove the rear brake drum 6 Remove the rear brake shoes from the brake support plate Refer to DRUM BRAKE SHOES in this REMOVAL AND INSTALLATION section NOTE If the brake shoes are wet with grease or brake fluid replace them 7 Remove the b
124. op braking hard enough to cause the ABS to cycle Again accelerate the vehicle past 25 mph Refer to the diagnostic manual for further test ing of the antilock brake system PL DIAGNOSIS AND TESTING Continued ABS ELECTRONIC DIAGNOSIS The following information is presented to give the technician a general background on the diagnostic capabilities of the ABS system Complete electronic diagnosis of the ABS system used on this vehicle is covered in the Chassis Diagnostic Procedures manual Electronic diagnosis of the ABS system used on this vehicle is performed using the DRBIII scan tool The vehicle s scan tool diagnostic connector is located under the steering column lower cover to the left side of the steering column Fig 10 80a793d0 Fig 10 ABS System Diagnostic Connector Location 1 DRIVER AIRBAG MODULE 2 PASSENGER AIRBAG MODULE 3 DATA LINK CONNECTOR ABS SELF DIAGNOSIS The ABS system is equipped with a self diagnosis capability which may be used to assist in the isola tion of ABS faults The features are described below START UP CYCLE The self diagnosis ABS start up cyde begins when the ignition switch is turned to the ON position Eledrical checks are completed on ABS components induding the CAB solenoid continuity and the relay system operation During this check the amber ABS warning lamp is turned on for approximately 5 sec onds and the brake pedal may emit a popping sound moving slight
125. or ward until the booster contacts the ABS ICU mount ing bracket 11 If the vehicle does not have antilock brakes carefully push the power brake booster forward one to two inches being careful not to stretch the brake lines from the master cylinder to the brakes 12 Remove the two nuts fastening the brake pedal bracket to the instrument panel support Fig 40 13 Carefully remove the brake pedal assembly by pulling the pedal bracket back toward the instru ment panel releasing the bracket from the booster studs Next tip the bracket down past the input rod guiding the rod through the gap left by the missing brace removed in Step 8 Remove the brake pedal assembly out from under the instrument panel 14 The pedal can be removed from it s bracket by grinding off the peened end of the shaft removing the shaft pedal and bushings A service parts pack age is available to replace these items INSTALLATION 1 If the pedal has been removed from it s bracket install the pedal bushings and bolt in shaft on the bracket using the available service parts pack age 2 Install the brake pedal assembly by tipping the pedal bracket and guiding the power brake booster mounting portion up past the booster input rod Guide the top of the bracket onto the studs protrud ing from the instrument panel support Fig 40 then guide the booster mounting portion onto the power brake booster mounting studs BRAKES 5 25 3 Push the
126. ove the steering column coupling pinch bolt Fig 38 the pinch bolt nut is caged to the coupling and is not removable Separate the upper and lower steering column couplings 4 Depress and hold the brake pedal while rotat ing the brake lamp switch Fig 39 in a counterclock wise direction approximately 30 degrees 5 Pull the switch rearward and remove it from its mounting bracket 6 Remove the clip securing the power brake booster input rod to the brake pedal Fig 39 Remove the input rod from the brake pedal 7 Remove the two upper nuts fastening the brake pedal bracket to the power brake booster Fig 40 PL Oa NA sa Zi GA o p I 80b 4e13 Fig 38 Steering Column Couplings 1 STEERING COLUMN UPPER COUPLING 2 PINCH BOLT 3 STEERING COLUMN LOWER COUPLING 4 BRAKE PEDAL 5 NUT 6 RETAINER PIN 80bcea48 Fig 39 Brake Lamp Switch 1 SWITCH 2 CLIP 3 BRAKE PEDAL 4 CONNECTOR 8 Carefully pry the tie bar running between the two upper booster mounting studs from its plastic retaining fasteners 9 Remove the two remaining nuts fastening the brake pedal bracket to the power brake booster Fig 40 PL REMOVAL AND INSTALLATION Continued 80bbc3b6 Fig 40 Brake Pedal Mounting 1 CLUTCH CABLE 2 BOOSTER MOUNTING NUTS 3 UPPER MOUNTING NUTS 10 If the vehicle is equipped with antilock brakes carefully push the power brake booster f
127. p switch into the bracket using the following procedure e Depress the brake pedal as far down as possible e Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket e When the switch is fully seated in its bracket rotate the switch clockwise approximately 30 to lock the switch into place CAUTION Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch If too much force is used the switch or striker can be damaged 7 Gently pull back on the brake pedal until the pedal stops moving This will ratchet the switch plunger backward to the correct adjustment position 8 Check the stop lamps to verify that they are operating properly and not staying on when the pedal is in the released position DRUM BRAKE SHOES 1 Verify the parking brake lever is in the fully released position 2 Raise the vehide Refer to HOISTING in the LUBRICATION AND MAINTENANCE group fro the proper lifting procedure 3 Remove the rear brake adjusting hole rubber plug from the rear brake shoe support plate Fig 126 Fig 126 Rear Brake Adjusting Hole Plug 1 REAR BRAKE SUPPORT PLATE 2 REAR STRUT 3 BRAKE ADJUSTING HOLE PLUG 5 62 BRAKES ADJ USTMENTS Continued 4 Insert a brake adjustment tool or a screw driver through the adjusting hole in support plate and against the star wheel of the adjuster screw Move
128. power brake booster back into mount ing position from under the hood 4 Install the two nuts fastening the brake pedal bracket to the instrument panel support Fig 40 Install the nuts all the way but do not tighten them at this time 5 Install the two lower power brake booster mounting nuts but do not tighten them at this time 6 Place the tie bar running between the two upper booster mounting studs onto the studs with the long flat side facing upward and the curved side downward 7 Install the two upper power brake booster mounting nuts on their studs 8 Tighten all four nuts fastening the brake pedal bracket to the power brake booster to a torque of 34 N m 300 in Ibs 9 Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 N m 300 in Ibs 10 Install the power brake booster input rod on the pin mounted on the side of the brake pedal Install a new retaining dip on the end of the pin Fig 39 Do not reuse the old clip NOTE Prior to installing the brake lamp switch make sure the plunger is at it s fully extended posi tion 11 Hold the brake lamp switch firmly in one hand Then using the other hand pull outward on the plunger of the brake lamp switch until it has ratcheted out to its fully extended position 12 Mount the brake lamp switch into the bracket using the following procedure e Depress the brake pedal as far down as possible e Inst
129. r If the fluid sep arates into layers there is mineral oil or other fluid contamination of the brake fluid If the brake fluid is contaminated drain and thor oughly flush the brake system Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including the master cylinder proportioning valves caliper seals wheel cylinder seals ABS hydraulic control unit and all hydraulic fluid hoses PL SERVICE PROCEDURES BRAKE FLUID LEVEL CHECKING CAUTION Use only Mopar brake fluid or an equiv alent from a tightly sealed container Brake fluid must conform to DOT 3 specifications Do not use petroleum based fluid because seal damage in the brake system will result Refer to SERVICE PROCEDURES in the BASE BRAKE SYSTEM section in this group for the proper procedure to check and adjust the brake fluid level in the master cylinder fluid reservoir ANTILOCK BRAKE SYSTEM BLEEDING The base brake s hydraulic system must be bled anytime air enters the hydraulic system The ABS though particularly the ICU HCU should only be bled when the HCU is replaced or removed from the vehide The ABS must always be bled anytime it is suspected that the HCU has ingested air Under most drcumstances that require the bleeding of the brakes hydraulic system only the base brake hydraulic system needs to be bled It is important to note that excessive air in the brake system will cause a soft or spongy feelin
130. rake wheel cylinder attaching bolts Fig 76 8 Remove the brake wheel cylinder from the brake support plate Fig 77 INSTALLATION 1 Install a new O ring at the mating surface of the wheel cylinder to brake support plate Fig 77 PL 9405 39 Fig 76 Brake Flex Hose At Wheel Cylinder 1 BRAKE SUPPORT PLATE 2 WHEEL CYLINDER ATTACHING BOLTS 3 REAR BRAKE FLEX HOSE TUBE 4 WHEEL CYLINDER ASSEMBLY AVL N Wh Fig 77 Remove install Wheel Cylinder 1 WHEEL CYLINDER 2 SUPPORT PLATE 3 O RING 9305 114 NOTE When installing wheel cylinder on brake support plate be sure it is positioned squarely hor izontal to the brake assembly 2 Install the wheel cylinder onto brake support plate Fig 77 Tighten the attaching bolts to a torque of 13 N m 115 in Ibs 3 Hand start the rear brake flex hose tube fitting to wheel cylinder Tighten the tube nut to a torque of 17 N m 145 in Ibs 4 Install the rear brake shoes on the brake sup port plate Replace them as necessary 5 Install the rear brake drum onto the rear hub PL REMOVAL AND INSTALLATION Continued 6 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 7 Adjust the rear brakes Refer to ADJ UST MENTS in this section of this service manual group 8 Lower the vehicle 9 Remove the brake pedal holder 10 Bleed the wheel cylinder
131. rce of contamination 2 Test proportioning valves folowing procedure listed in diagnosis and testing section Replace valves as necessary 3 Refer to the ABS section and Chassis Diagnostic Procedures manual 4 Refer to power brake booster in the diagnosis and testing section STOP LAMPS STAY ON 1 Brake lamp switch out of adjustment 2 Brake pedal binding 3 Obstruction in pedal linkage 4 Power Brake Booster not allowing pedal to return completely 1 Adjust brake lamp switch 2 Inspect and replace as necessary 3 Remove obstruction 4 Replace power brake booster VEHICLE PULLS TO RIGHT OR LEFT ON BRAKING 1 Frozen brake caliper piston 2 Contaminated brake shoe lining 3 Pinched brake lines 4 Leaking piston seal 5 Suspension problem 1 Replace frozen piston or caliper Bleed brakes 2 Inspect and clean or replace shoes Repair source of contamination 3 Replace pinched line 4 Replace piston seal or brake caliper 5 Refer to the Suspension group PARKING BRAKE EXCESSIVE HANDLE TRAVEL 1 Rear brakes out of adjustment 1 Adjust rear drum brake shoes or rear parking brake shoes on vehicles with rear disc brakes POWER BRAKE BOOSTER BASIC TEST 1 With engine off depress and release the brake pedal several times to purge all vacuum from the power brake booster 2 Depress and hold the pedal with light effort 15 to 25 Ibs pressure then start the en
132. review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL CAUTION The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved 1 With the engine not running pump the brake pedal 4 5 strokes until the pedal feel is firm 2 Disconnect the negative ground cable from the battery and isolate the cable 3 Disconnect the positive cable from the battery then remove the battery from the battery tray There is one nut securing the clamp on the backside of the battery holding it in place 4 Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir Fig 44 eee Se o FO NAN AN TANI ko A NG FE INZ 80bbc363 Fig 44 Master Cylinder 1 POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG 2 POWER BRAKE BOOSTER 3 BRAKE FLUID PRESSURE SWITCH 4 MASTER CYLINDER PL 5 Disconnect the two brake tubes from the mas ter cylinder and two brake tubes from the propor tioning valves Fig 45 Install plugs at all of the open brake tube outlets on the master cylinder 80bbc364 Fig 45 Brake Tubes At Master Cylinder RIGHT FRONT BRAKE TUBE LEFT FRONT BRAKE TUBE LEFT REAR BRAKE TUBE RE
133. right rear brakes are on one hydraulic circuit and the right front and left rear are on the other Vehicles equipped with the optional antilock brake system ABS use a system designated Mark 20e This system shares most base brake hardware used on vehicles without ABS A vehicle equipped with ABS however uses a different master cylinder and brake tubes Also included in the ABS system is an integrated control unit ICU and four wheel speed sensors These components are described in detail in the ANTILOCK BRAKE SYSTEM section in this group of the service manual All vehicles with ABS come standard with four wheel disc brakes and trac tion control The parking brakes are hand operated When applied the parking brake lever pulls on cables that actuate brake shoes at each rear wheel The parking brake lever has an automatic adjusting feature that takes up any excessive slack in the parking brake cable system BASE BRAKE SYSTEM COMPONENTS BRAKE PEDAL A suspended type brake pedal is used on this vehi cle The pedal pivots on a shaft mounted in the pedal support bracket under the instrument panel The pedal connects to the power brake booster input rod and pushes it in when the pedal is applied The brake pedal and it s pad are serviceable sepa rately PL POWER BRAKE BOOSTER There are two different power brake booster designs although externally they appear the same All vehicles use a 205 mm tandem diaphragm power brake boos
134. rol system is activated 4 store diagnostic information 5 provide communication to the DRB scan tool while in diagnostic mode The CAB constantly monitors the antilock brake system for proper operation If the CAB detects a fault it will send a message to the mechanical instu ment cluster MIC instructing it to turn on the amber ABS warning lamp and disable the antilock braking system The normal base braking system will remain operational The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock When a wheel locking tendency is detected the CAB commands the CAB command coils to actu ate The CAB command coils then open and close the valves in the HCU that modulate brake fluid pres sure in some or all of the hydraulic circuits The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present The CAB contains a self diagnostic program that monitors the antilock brake system for system faults When a fault is detected the amber ABS warning lamp is turned on and the fault diagnostic trouble code DTC is then stored in a diagnostic program memory These DTC s will remain in the CAB mem ory even after the ignition has been turned off The DTC s can be read and cleared from the CAB mem ory by a technician using the DRB scan tool If not cleared with a DRB scan tool the fault
135. ry Refer to ADJ USTMENTS in this section of this service manual group 4 Lower the vehicle DRUM BRAKE SHOE SUPPORT PLATE REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Using a brake pedal holding tool as shown Fig 88 depress the brake pedal past its first one inch of travel and hold it in this position This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir 2 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the rear tire and wheel assembly from the vehicle 4 Disconnect the rear brake flex hose from the wheel cylinder Fig 89 5 Remove the rear brake drum 6 Remove the dust cap Fig 90 from the rear hub and bearing 7 Remove the nut Fig 91 holding the rear hub and bearing to the spindle Remove the hub and bearing from the spindle 8 Remove the rear brake shoes from the brake support plate Refer to DRUM BRAKE SHOES in this REMOVAL AND INSTALLATION section KO AT rae 9 9505 238 Fig 88 Brake Pedal Holding Tool 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL a Q G
136. s Refer to ADJ USTMENTS in this section of this service man ual group 16 Lower the vehicle 17 Road test vehicle stopping in both the forward and reverse directions The automatic adjuster will continue to adjust the brakes during the road test of the vehicle BRAKE DRUM REAR REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear tire and wheel assembly from the vehicle 3 Remove the brake drum retaining clips if equipped Fig 87 80bcea46 Fig 87 Drum Brakes 1 DUST CAP 2 NUT 3 DRUM 4 HUB AND BEARING 5 WHEEL CYLINDER 6 SEAL 7 SUPPORT PLATE 8 BRAKE SHOES 9 RETAINER CLIP 5 46 BRAKES REMOVAL AND INSTALLATION Continued 4 Remove the brake drum Fig 87 NOTE If the drum does not come off further brake clearance can be obtained by backing off the brake automatic adjuster screw Remove the rubber plug from the top of brake support plate Rotate the automatic adjuster screw in an upward motion using a screwdriver INSTALLATION NOTE Before installing the drum inspect the brake shoe linings for wear shoe alignment and contam ination 1 Install the rear brake drum on rear hub and bearing Fig 87 2 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 3 Adjust the rear brake shoes as necessa
137. s sleeves and two guide pin bolts Fig 5 The guide pin bolts thread directly into bosses on the steering knuckle Two machined abutments on the steering knuckle position the caliper The guide pin bolts sleeves and bushings control the side to side movement of the caliper All of the front brake force generated during braking of the vehicle is taken up directly by the steering knuckles of the vehicle BRAKE SHOES AND LININGS There are two brake shoes mounted to each caliper one inboard and one outboard Fig 5 When brake shoes are replaced only brake shoes meeting the original equipment manufacturer OEM formulation such as Mopar replacement parts should be used As front disc brake shoe linings wear master cyl inder reservoir brake fluid level will drop Fluid level should be checked after replacing shoes Front disc brakes are equipped with an audible wear indicator on the outboard brake pad Fig 5 This sensor emits a sound when the brake lining may need inspection or replacement PL DESCRIPTION AND OPERATION Continued BRAKES 5 5 80500563 Fig 5 Front Disc Brake Caliper 10 BRAKE SHOE 11 BRAKE SHOE 12 ANTI RATTLE CLIP CALIPER GUIDE PIN BOLT SLEEVE BUSHING CALIPER PISTON SEAL PISTON DUST SEAL WEAR INDICATOR ANTI RATTLE CLIP O DN OD ARA ON PR747B Fig 6 Piston Seal Function PISTON CYLINDER BORE PISTON SEAL BRAKE PRESSURE OFF CALIPER HOU
138. s ratch eted out to its fully extended position 10 Mount the brake lamp switch into the bracket using the following procedure e Depress the brake pedal as far down as possible e Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket e When the switch is fully seated in its bracket rotate the switch clockwise approximately 30 to lock the switch into place CAUTION Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch If too much force is used the switch or striker can be damaged 11 Gently pull back on the brake pedal until the pedal stops moving This will ratchet the switch plunger backward to the correct adjustment position 12 Install the instrument panel Refer to the INSTRUMENT PANELS AND SYSTEMS group in this service manual for the required procedure 13 Check the stop lamps to verify they are oper ating properly and not staying on when the pedal is in the released position 14 Road test the vehicle to ensure proper opera tion of the brakes BRAKE LAMP SWITCH REMOVAL 1 Depress and hold the brake pedal while rotat ing the brake lamp switch Fig 43 in a counterclock wise direction approximately 30 degrees BRAKES 5 27 2 Pull the switch rearward and remove it from its mounting bracket 3 Disconnect the wiring harness connector from the brake lamp switch 80bcea48 F
139. s switched off and the inlet valve is pulsed This increases the pressure to the rear brakes This back and forth pro cess will continue until the required slip difference is obtained At the end of EBD braking brakes released the fluid in the LPA drains back to the PL master cylinder by switching on the outlet valve and draining through the inlet valve check valve At the same time the inlet valve is switched on in case of another brake application The EBD will remain functional during many ABS fault modes If both the red BRAKE and amber ABS warning lamps are illuminated the EBD may not be functioning TRACTION CONTROL SYSTEM Traction control reduces wheel slip and maintains traction at the driving wheels at speeds below 56 kph 35 mph when road surfaces are slippery The trac tion control system reduces wheel slip by braking the wheel that is losing traction The CAB monitors wheel speed During accelera tion if the CAB detects front drive wheel slip and the brakes are not applied the CAB enters traction control mode Traction control operation proceeds in the following order 1 Close the normally open traction control TC valves 2 Start the pump motor and supply volume and pressure to the front drive hydraulic circuit The pump motor runs continuously during traction con trol operation 3 Open and close the build and decay solenoid valves to maintain minimum wheel slip and maxi mum traction The cy
140. sc brake system use a different lining material on the front disc brake shoes than vehicles with front disc and rear drum brakes When new brake shoes are installed be sure the brake shoes for the correct type of brake system are used REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove both front tire and wheel assemblies from vehicle 3 Begin on one side of the vehicle 4 Remove the two brake caliper guide pin bolts Fig 59 5 Remove the disc brake caliper from the steer ing knuckle The caliper is removed by first tipping either the top right side caliper or bottom left side caliper of the caliper away from the brake rotor then pulling the caliper off the opposite end s caliper slide abutment on the knuckle and brake rotor 6 Support the caliper using a wire or cord to pre vent the weight of caliper from damaging the brake hose Fig 60 Do not let the caliper hang by the brake hose BRAKES 5 35 80bce90a Fig 59 Caliper And Rotor Mounting 1 RETAINER CLIP 2 BRAKE ROTOR 3 HUB 4 GUIDE PIN BOLTS 5 DISC BRAKE CALIPER 9402 23 Fig 60 Supporting Caliper 1 WIRE HANGER 2 STEERING KNUCKLE 3 BRAKE DISC 4 DISC BRAKE CALIPER ASSEMBLY 5 BRAKE HYDRAULIC HOSE 5 36 BRAKES REMOVAL AND INSTALLATION Continued 7 Remove the outboard brake shoe from the cali per by prying the shoe r
141. t Fig 104 20 Remove the parking brake cable and sealing grommet from floor pan of the vehide 2 SHIELD MOUNTING SCREWS 3 REAR PARKING BRAKE CABLE INSTALLATION 1 From underneath push the parking brake cable through the hole in the floor pan of the vehicle mak ing sure the cable sealing grommet is installed in the floor pan as far as possible to insure a good seal 2 Attach the parking brake cable routing bracket to the tension strut mounting bolt Install and tighten the mounting nut to a torque of 28 N m 250 in Ibs 5 52 BRAKES REMOVAL AND INSTALLATION Continued 80bbc3a7 Fig 103 Parking Brake Cable Removal 1 CABLE RETAINER 2 OFFSET BOX WRENCH 3 PARKING BRAKE CABLE Fig 104 Cable At Tension Strut 1 TENSION STRUT MOUNTING BOLTS 2 TENSION STRUT 3 SPOOL BUSHING 4 NUT 5 PARKING BRAKE CABLE 3 Install the parking brake cable into the brake support plate or the rear disc brake adapter Be sure the locking fingers on the cable retainer are expanded once the cable is pushed all the way into the support plate or brake adapter hole to ensure the cable is securely held in place 4 On vehicles equipped with rear drum brakes e Install the parking brake cable on the parking brake cable actuating lever Fig 99 e Install the actuating spring to the brake shoe and the brake adjustment lever Fig 100 5 On vehicles equipped with rear disc brakes PL e I
142. t Fig 48 Tighten the two bolts and nuts to a torque of 34 N m 25 ft Ibs 10 Reinstall the air deaner box onto its grom meted alignment post Fig 48 11 Install the one nut and one bolt securing the air cleaner box in place then connect the wiring har ness connector at the air inlet sensor 12 Install the battery and damp it in place 13 Connect the positive then the negative ground cable on the battery 14 Adjust the stop lamp switch as necessary Refer to STOP LAMP SWITCH in the ADJ UST MENTS section of this group 15 Bleed the base brake system 16 Road test the vehicle to ensure proper opera tion of the brakes PROPORTIONING VALVE NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Using a brake pedal holder depress the brake pedal past its first one inch of travel and hold it in this position Fig 53 This will isolate the master cylinder from the brake hydraulic system and will PL not allow the brake fluid to drain out of the master cylinder reservoir L IK NN N 9505 238 Fig 53 Brake Pedal Holder 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL 2 Disconned the brake tube from the proportion ing valve requiring removal Fig 54
143. ter The two boosters are internally tuned differently depending on whether the vehicle is equipped with the standard front disc rear drum brake combination or the optional front disc rear disc four wheel disc brake combination If the power brake booster requires replacement be sure it is replaced with the correct part The power brake booster can be identified by the tag attached to the body of the booster assembly Fig 1 This tag contains the following information The production part number of the power brake booster the date it was built and who manufactured it 80bbc363 Fig 1 Master Cylinder and Power Brake Booster 1 POWER BRAKE BOOSTER PARTS IDENTIFICATION TAG 2 POWER BRAKE BOOSTER 3 BRAKE FLUID PRESSURE SWITCH 4 MASTER CYLINDER The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop the vehicle The power brake booster is vacuum operated The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve Fig 2 As the brake pedal is depressed the power booster input rod moves forward This opens and closes valves in the power brake booster allowing atmo spheric pressure to enter on one side of a diaphragm Engine vacuum is always present on the other side This difference in pressure forces the output rod of the power booster out against the primary piston of the master cylinder As
144. ter cylinder housing Fig 47 BRAKES 5 29 80bbc366 Fig 46 Master Cylinder Reservoir 1 BRAKE FLUID LEVEL SWITCH RETAINING TABS 2 RESERVOIR RETAINING PINS 3 SEAL 80bbe3ag Fig 47 Sealing Grommets 1 MASTER CYLINDER 2 GROMMETS 3 SEAL INSTALLATION 1 Install new sealing grommets in the master cylinder housing Fig 47 2 Lubricate the sealing grommets with fresh clean DOT 3 brake fluid Place the reservoir in posi tion over the grommets making sure the filler hole is towards the front of the vehicle Seat the reservoir into the grommets While holding the reservoir firmly against the grommets install the two plastic pins previously removed through their mounting holes until they protrude out the other side of the master cylinder reservoir Fig 46 3 Connect the brake fluid level switch wiring connector Fig 44 5 30 BRAKES REMOVAL AND INSTALLATION Continued 4 Fill the reservoir with fresh clean DOT 3 brake fluid Refer to BRAKE FLUID LEVEL CHECKING in the SERVICE PROCEDURES section in this sec tion of this service manual group BRAKE FLUID LEVEL SWITCH NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir Fig 44 2 Push together the retaining
145. the cal iper Fig 64 6 Lubricate both steering knuckle caliper slide abutments with a liberal amount of Mopar Multi purpose Lubricant or an equivalent CAUTION Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses PL REMOVAL AND INSTALLATION Continued 80b1196a Fig 64 Installing Outboard Brake Shoe 1 BRAKE SHOE ASSEMBLY 2 BRAKE CALIPER 7 Install the disc brake caliper with pads on the brake rotor and steering knuckle The left side cali per is installed by first sliding the top of the caliper past the top caliper slide abutment on the steering knuckle to hook the top edge of the caliper then pushing the lower end of the caliper into place against the knuckle Fig 65 The right side caliper is installed by first sliding the bottom edge of the cal iper past the lower caliper slide abutment on the steering knuckle to hook the lower edge of the cali per then pushing the top of the caliper into place against the steering knuckle 80aa4b6d Fig 65 Installing Left Caliper 1 SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT OF STEERING KNUCKLE AS SHOWN 2 BRAKING DISC 3 DISC BRAKE CALIPER 4 STEERING KNUCKLE BRAKE ABUTMENT BRAKES 5 37 8 Install the caliper guide pin bolts and tighten them to a torque of 22 N m 192 in Ibs Fig 59 9 Install the tire and
146. the handle of tool downward to adjust the brake drag Rotate the tire and wheel assembly while adjusting the adjuster screw Continue to adjust the shoes until a slight drag is noticed when the tire and wheel assembly is rotated NOTE In the event the brake shoes are over ad justed the adjuster can be backed off using the fol lowing step If not proceed to step 6 5 If the shoes are in the over adjusted position insert a thin screwdriver into brake adjusting hole and push back the adjusting lever out of engagement with star wheel Fig 127 Take care not to bend the adjusting lever While holding the adjusting lever out of engagement with star wheel back off the star wheel until the tire and wheel assembly is free to turn without dragging Repeat the adjustment proce dure Fig 127 Backing Off Brake Adjuster Screw 1 MEDIUM SCREWDRIVER 2 BRAKE ADJUSTING HOLE 3 THIN SCREWDRIVER OR WELDING ROD 6 Install adjusting hole rubber plug Fig 126 7 Repeat the above adjustment procedure to the other side brakes 8 Apply and release the park brake lever one time after the adjustment process is completed so the parking brakes can readjust themselves to the new brake shoe adjustment PARKING BRAKE SHOES REAR DISC BRAKES NOTE The parking brake shoes used in the drum in hat park brake system do not automatically adjust to compensate for brake shoe lining wear PL Therefore it is necessary to manually
147. the pistons in the master cyl inder move forward hydraulic pressure is created in the brake system PL DESCRIPTION AND OPERATION Continued 80bcea47 Fig 2 Power Brake Booster 1 MOUNTING STUD 2 PARTS IDENTIFICATION TAG 3 MASTER CYLINDER MOUNTING STUDS 4 VACUUM CHECK VALVE The power brake vacuum booster assembly mounts on the engine side of the dash panel The booster input push rod connects to the brake pedal A vac uum line connects the power booster to the intake manifold The master cylinder is bolted to the front of the power brake booster MASTER CYLINDER The base brakes on a vehicle not equipped with ABS use a standard compensating port master cylin der while vehicles equipped with ABS use a center valve design master cylinder The information pro vided here applies only to the non ABS master cylin der For information on the master cylinder used on vehicles with ABS refer to the ANTILOCK BRAKE SYSTEM section in this service manual group The non ABS master cylinder is a four outlet design with two screw in proportioning valves One is attached directly to the inboard side of the master cylinder housing while the other is attached to the bottom Fig 3 Vehicles equipped with rear drum brakes use a master cylinder with a 22 23 mm 0 875 in bore diameter while vehicles equipped with rear disc brakes use a 23 82 mm 0 937 in bore diameter master cylinder The master cylinder body is an anodized
148. the way using a wire hanger or cord e Remove the brake rotor from the rear hub and bearing 14 Remove the dust cap from the rear hub and bearing 5 50 BRAKES _ i qO cm Pc REMOVAL AND INSTALLATION Continued 15 Remove the hub and bearing retaining nut from the knuckle spindle then remove the hub and bearing Fig 97 16 On vehicles equipped with rear disc brakes remove the upper return spring both shoe hold down clips then spread the rear parking brake shoes apart at the top enough to clear the shoe anchor and remove the parking brake shoes as an assembly from the disc brake adapter Fig 98 Were JR 80bbc3a4 Fig 96 Compressing Cable Retainer 1 CARPET ROLLED FORWARD 2 WRENCH 3 RIGHT REAR CABLE 4 REAR PARKING BRAKE CABLES amp 5 LEFT REAR CABLE uda G 80bbc3a5 Fig 98 Parking Brake Shoes 1 UPPER RETURN SPRING 2 SHOE HOLD DOWN CLIPS 3 ADJUSTER 4 LOWER REAR SPRING 5 DISC BRAKE ADAPTER 17 To remove the rear parking brake cable from the brake support plate on vehides equipped with 80bce90f rear drum brakes e Remove the parking brake cable from the park Fig 97 Rear Disc Brakes ing brake actuating lever Fig 99 1 DISC BRAKE CALIPER e Remove the actuating spring between the brake 2 DISC BRAKE ADAPTER shoe adjustment lever and the brake shoe Fig 100
149. tor if it will cause the rotor to fall below minimum thickness Minimum thickness specifications are cast on the rotor s unmachined surface Fig 14 Limits can also be found in the table at the end of this brake rotor information 80aa4b6a Fig 14 Minimum Brake Rotor Thickness Markings Typical 1 ROTOR MINIMUM THICKNESS MARKING 2 ROTOR ROTOR THICKNESS VARIATION Thickness variation in a rotor s braking surface can result in pedal pulsation chatter and surge This can also be caused by excessive runout in the rotor or the hub Rotor thickness variation measurements should be made in conjunction with measuring runout Mea sure thickness of the brake rotor at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm 1 inch from edge of rotor Fig 15 If thickness measurements vary by more than 0 013 mm 0 0005 inch the rotor should refaced or replaced Refer to SERVICE PROCE DURES in this section of this group for information on brake rotor machining ROTOR RUNOUT On vehicle rotor runout is the combination of the individual runout of the hub face and the runout of BRAKES 5 13 TWELVE EQUAL POINTS ON DISC M Fig 15 Checking Rotor For Thickness 1 CALIPER the rotor The hub and rotor runouts are separable To measure rotor runout on the vehicle first remove the tire and wheel assembly Reinstall the wheel mounting nuts on t
150. ubes from the master cylinder Fig 15 Install plugs in the master cylinder outlet ports 8 Disconnect the 25 way connector from the con troller antilock brake CAB mounted on the inte grated control unit ICU and move it out of the way The connector is disconnected by pulling outward on the connector lock Fig 16 This will unlock and raise the 25 way connector out of the socket on the CAB PL 80bbc3b2 Fig 15 Brake Tube Locations 1 PRIMARY BRAKE TUBE 2 SECONDARY BRAKE TUBE 3 BRAKE TUBES FROM MASTER CYLINDER 4 BRAKE TUBES TO BRAKES 7 a NN N Na N NAA NAAA X X A A A A A AA O Fig 16 Connector Lock Pulled Outward 1 MASTER CYLINDER 2 25 WAY CONNECTOR 3 CAB 4 CONNECTOR LOCK PULLED OUTWARD 5 ICU 9 Tag the brake tubes coming from the master cylinder as primary and secondary Fig 15 This is done to avoid mix up once the tubes are removed from the vehicle 10 Disconnect and remove the primary and sec ondary brake tubes coming from the master cylinder at the ICU hydraulic control unit HCU Fig 15 11 Disconnect the brake tubes going to each indi vidual brake at the HCU Fig 15 12 Remove the 3 bolts attaching the ICU to its mounting bracket Fig 17 13 Remove the ICU from the vehicle PL REMOVAL AND INSTALLATION Continued CI s 80bbc3b3 Fig 17 ICU Mounting Bolts 1 ICU 2 ICU MOUNTING BOLTS
151. ucking in any contamination This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved 1 With the engine not running pump the brake pedal 4 5 strokes until the pedal feel is firm 2 Disconnect the negative ground cable from the battery and isolate the cable 3 Disconnect the positive cable from the battery then remove the battery from the battery tray There is one nut securing the clamp on the backside of the battery holding it in place 4 Disconnect the wiring harness connector from the brake fluid level switch on the master cylinder reservoir Fig 12 PL REMOVAL AND INSTALLATION Continued 5 Disconnect the primary and secondary brake tubes from master cylinder Fig 12 Install plugs in the master cylinder outlet ports 80bbc362 Fig 12 Master Cylinder 1 POWER BRAKE BOOSTER 2 CONNECTOR 3 BRAKE FLUID LEVEL SWITCH 4 MOUNTING NUTS 5 SECONDARY BRAKE TUBE 6 PRIMARY BRAKE TUBE 6 Clean the area around where the master cylin der attaches to the power brake booster using a suit able brake cleaner such as Mopar Brake Parts Cleaner or an equivalent 7 Remove the 2 nuts attaching master cylinder to power brake booster Fig 12 8 Slide the master cylinder straight out of the power brake booster INSTALLATION NOTE The master cylinder must be bled before installing it on the vehicle 1 Bleed the master cylinder before i
152. um to exceed maximum allowable diameter do not machine the brake drum It needs to be replaced CAUTION Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter All brake drums are marked with the maximum allowable brake drum diameter Fig 35 80aa4b6b Fig 35 Brake Drum Maximum Diameter Identification 1 HUB BEARING ASSEMBLY 2 WHEEL MOUNTING STUDS 3 BRAKE DRUM MAXIMUM DIAMETER MARKING 4 REAR BRAKE DRUM When machining make sure the final finish feed cut is fine in order to avoid a screw effect on the brake shoes when the brakes are applied This final feed cut specification varies from lathe manufacturer to lathe manufacturer PARKING BRAKE AUTOMATIC ADJUSTER LOCK OUT WARNING THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 25 POUNDS DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY WARNING WHEN REPAIRS TO THE PARKING BRAKE LEVER OR CABLES ARE REQUIRED THE AUTOMATIC ADJUSTER MUST BE LOADED AND LOCKED OUT TO AVOID POSSIBLE INJURY ADJUSTER LOADING AND LOCKING OUT 1 Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever
153. ures brittleness or damage to the piston dust boot If the boot is damaged or a PL fluid leak is visible disassemble the caliper assembly and install a new seal and boot and a piston if it is scored Refer to DISC BRAKE CALIPER in the DIS ASSEMBLY AND ASSEMBLY section in this section of this service manual group Check the guide pin dust boots to determine if they are in good condition Replace if they are damaged dry or found to be brittle Refer to DISC BRAKE CALIPER in the DISASSEMBLY AND ASSEMBLY section in this section of this service manual group DRUM BRAKES REAR BRAKE SHOES Clean the rear brake shoes and springs with a water dampened cloth or with a brake cleaner Do not use a petroleum based product Rear brake shoe lining should show contact across the entire width of the lining and also from the heel to the toe of the lining Replace the shoes if noted otherwise Brake shoes with lack of contact at the toe or heel of the brake shoe lining may be improperly ground Clean and inspect the brake support plate and shoe adjuster screw Apply a thin coat of Mopar Multi Purpose Lubricant or equivalent to the threads of the self adjuster Fig 124 Replace the adjuster screw if it is corroded NOTE Adjuster screws are different side to side Left side adjuster screws have left hand threads and right side adjuster screws have right handed threads Fig 124 Adjuster Screw And Lever Typical 1 OUTBOARD FOR
154. way connector in the socket of the CAB and carefully push it down as far as possi ble Fig 16 e When the connector is fully seated into the CAB socket push the connector lock inward This pulls the connector into the socket of the CAB and locks it in the installed position 8 Position the battery tray back in place Install the two bolts then the two nuts mounting the bat tery tray to its bracket Fig 14 Tighten the two bolts and nuts to a torque of 15 N m 135 in Ibs 9 Reinstall the air cleaner box onto its grom meted alignment post Fig 14 10 Install the one nut and one bolt securing the air cleaner box in place then conned the wiring har ness connector at the air inlet sensor 11 Install the battery and damp it in place Tighten the hold down clamp bolt to a torque of 12 N m 105 in Ibs 12 Connect the positive ground cable on the battery 13 Bleed the base and the ABS hydraulic sys tems Refer to ANTILOCK BRAKE SYSTEM BLEEDING in this section of this service manual group 14 Fill the master cylinder to the proper fill level 15 Road test the vehicle to ensure proper opera tion of the base and antilock brake systems WHEEL SPEED SENSOR FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section then the negative REMOVAL 1 Raise the vehide Refer to HOISTING in the LUBRICATION AND MAI
155. wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m 100 ft Ibs 10 Repeat the above procedure to the front brakes on the other side of the vehicle 11 Lower the vehicle 12 Pump the brake pedal before moving the vehi cle to set the brake shoes to the brake rotor 13 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads BRAKE ROTOR FRONT REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the front tire and wheel assembly 3 Remove the front disc brake caliper assembly from the brake rotor and store it out of the way Refer to DISC BRAKE SHOES FRONT in this REMOVAL AND INSTALLATION section of this ser vice manual group 4 Remove the clips retaining the brake rotor Fig 59 5 Remove the brake rotor by pulling it straight off the wheel mounting studs INSTALLATION 1 Install the brake rotor over the wheel mount ing studs and onto the hub Fig 59 2 Install the front disc brake caliper It may be necessary to retract the brake caliper piston back into the caliper to fit the shoes onto the rotor if a new rotor is being installed Refer to DISC BRAKE SHOES FRONT in this REMOVAL AND INSTAL LATION section of this service manual group 3 Install the tire and wheel assembly Tighten the wheel mounting nuts to a torque of 135 N m
156. with a brake cleaner Do not use a petroleum based product If a visual inspection does not adequately deter mine the condition of the lining a physical check will be necessary Remove the front disc brake shoes Refer to DISC BRAKE SHOES in the REMOVAL AND INSTALLA TION section in this section of this service manual group The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly When a set of brake shoes are worn to a total thickness of approximately 7 95 mm 5 16 inch or less they should be replaced Replace both brake shoe assemblies inboard and outboard It is necessary that both front wheel sets be replaced whenever brake shoe assemblies on either side are replaced 5 60 BRAKES CLEANING AND INSPECTION Continued If the brake shoe assemblies do not require replacement reinstall the assemblies making sure each brake shoe is returned to the original position Refer to DISC BRAKE SHOES in the REMOVAL AND INSTALLATION section in this section of this service manual group CALIPER INSPECTION Check for brake fluid leaks in and around the boot area Check for any ruptures brittleness or damage to the piston dust boot If the boot is damaged or a fluid leak is visible disassemble the caliper assembly and install a new seal and boot and a piston if it is scored Refer to DISC BRAKE CALIPER in the DIS ASSEMBLY AND ASSEMBLY section in this section of this service manual
157. with the recommended retaining clips DISC BRAKE CALIPER FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Using a brake pedal holding tool as shown Fig 55 depress the brake pedal past its first one inch of travel and hold it in this position This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened L 9505 238 Fig 55 Brake Pedal Holding Tool 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL 2 Raise the vehide Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the front tire and wheel assembly 5 34 BRAKES REMOVAL AND INSTALLATION Continued 4 Remove the banjo bolt connecting the brake hose to the brake caliper Fig 56 There are two washers one on each side of the flex hose fitting that will come off with the banjo bolt Inspect and discard these if they are worn or damaged VA WE 80bcea49 Fig 56 Brake Hose Connection 1 CALIPER 2 HOSE 3 BOLT 5 Remove the two brake caliper to steering knuckle guide pin bolts Fig 57 80bce90a Fig 57 Caliper Mounting 1

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