Adjustments

Rear drum brake

The rear drum brakes are equipped with a self-adjusting mechanism. Under normal circumstances, the only time adjustment is required is when the shoes are replaced, removed for access to other parts, or when one or both drums are replaced.

Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate.

ADJUSTMENT WITH BRAKE GAUGE

(1) Be sure parking brakes are fully released.

(2) Raise rear of vehicle and remove wheels and brake drums.

(3) Verify that left and right automatic adjuster levers and cables are properly connected.

(4) Insert brake gauge in drum. Expand gauge until gauge inner legs contact drum braking surface.

Then lock gauge in position (Fig. 57).

Fig. 57 Adjusting Gauge On Drum Fig. 57 Adjusting Gauge On Drum

1 - BRAKE GAUGE

2 - BRAKE DRUM

(5) Reverse gauge and install it on brake shoes.

Position gauge legs at shoe centers as shown (Fig.

58). If gauge does not fit (too loose/too tight), adjust shoes.

Fig. 58 Adjusting Gauge On Brake Shoes Fig. 58 Adjusting Gauge On Brake Shoes

1 - BRAKE GAUGE

2 - BRAKE SHOES

(6) Pull shoe adjuster lever away from adjuster screw star wheel.

(7) Turn adjuster screw star wheel (by hand) to expand or retract brake shoes. Continue adjustment until gauge outside legs are light drag-fit on shoes.

(8) Install brake drums and wheels and lower vehicle.

(9) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8-10 times to operate automatic adjusters and equalize adjustment.

NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters.

ADJUSTMENT WITH ADJUSTING TOOL

(1) Be sure parking brake lever is fully released.

(2) Raise vehicle so rear wheels can be rotated freely.

(3) Remove plug from each access hole in brake support plates.

(4) Loosen parking brake cable adjustment nut until there is slack in front cable.

(5) Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel (Fig. 59).

Fig. 59 Brake Adjustment Fig. 59 Brake Adjustment

1 - STAR WHEEL

2 - LEVER

3 - BRAKE SHOE WEB

4 - SCREWDRIVER

5 - ADJUSTING TOOL

6 - ADJUSTER SPRING

(6) Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated.

(7) Push and hold adjuster lever away from star wheel with thin screwdriver.

(8) Back off adjuster screw star wheel until brake drag is eliminated.

(9) Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels.

(10) Install support plate access hole plugs.

(11) Adjust parking brake cable and lower vehicle.

(12) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8-10 times to operate automatic adjusters and equalize adjustment.

NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters.

Park brake cable tensioner

NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation.

(1) Raise vehicle.

(2) Back off cable tensioner adjusting nut create slack in cables.

(3) Remove rear wheel/tire assemblies. Then remove brake drums.

(4) Verify brakes are in good condition and operating properly.

(5) Verify park brake cables operate freely and are not binding, or seized.

(6) Check rear brake shoe adjustment with standard brake gauge.

(7) Install drums and verify that drums rotate freely without drag.

(8) Install wheel/tire assemblies.

(9) Lower vehicle enough for access to park brake foot pedal. Then fully apply park brakes.

NOTE: Leave park brakes applied until adjustment is complete.

(10) Raise vehicle again.

(11) Mark tensioner rod 6.35 mm (1/4 in.) from edge of tensioner if no mark is visible (Fig. 60).

NOTE: The rod is marked from the factory.

(12) Tighten adjusting nut on tensioner until the 1/4 inch mark is no longer visible.

CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment.

(13) Lower vehicle until rear wheels are 15-20 cm (6-8 in.) off shop floor.

(14) Release park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower vehicle.

Fig. 60 Adjustment Mark On Cable Tensioner Rod Fig. 60 Adjustment Mark On Cable Tensioner Rod

1 - CABLE CONNECTOR

2 - ADJUSTER NUT

3 - 6.35MM (1/4 IN.)

Specifications

Brake fluid

The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 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 of brake fluid will absorb moisture from the air and contaminate the fluid.

CAUTION: Never use any type of a petroleumbased 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.

Base brakes

Disc Brake Caliper

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding

Bore . . . . . . . . . . . . . . . . . . . . . . 70 mm (2.75 in.)

Disc Brake Rotor

Type . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilated

Dimensions . . . . . . . 287 x 24 mm (11.3 x 0.9 in.)

Max. Runout . . . . . . . . . . . . . . 0.102 mm (0.004)

Max. Thickness Variation . . . . . . . . . . 0.013 mm (0.0005 in.)

Min. Rotor Thickness . . . . . 22.6 mm (0.8898 in.)

Brake Drum

Dimensions . . . . . . . . 279 x 57 mm (11 x 2.25 in.)

Max. Runout . . . . . . . . . . . . . 0.20 mm (0.008 in.)

Max. Diameter Variation . . . 0.076 mm (0.003 in.)

Brake Booster

Type . . . . . . . . . . . . . . . . . . . Tandem Diaphragm

Master Cylinder

Bore . . . . . . . . . . . . . . . . . . . . . 29 mm (1.125 in.)

Torque chart

DESCRIPTION   TORQUE

Brake Booster

Mounting Nuts . . . . . . . . . . 28 N*m (250 in. lbs.)

Master Cylinder

Mounting Nuts . . . . . . . . . . 18 N*m (160 in. lbs.)

Caliper

Mounting Pins . . . . . . . . . . . . 30 N*m (22 ft. lbs.)

Wheel Cylinder

Bolts . . . . . . . . . . . . . . . . . . . 20 N*m (15 ft. lbs.)

Combination Valve

Bolt (RWAL) . . . . . . . . . 20-27 N*m (15-20 ft. lbs.)

Bolt (ABS) . . . . . . . . . . . 10-13 N*m (7-10 ft. lbs.)

Support Plate

Mounting Bolts/Nuts . . . . . . . . 64 N*m (47 ft. lbs)

Brake Line Fittings

Master Cylinder . . . . . . . . . 19 N*m (170 in. lbs.)

Combination Valve . . . . . . . 19 N*m (170 in. lbs.)

Wheel Cylinder . . . . . . . . . . 16 N*m (145 in. lbs.)

Brake Hose

Front Fitting . . . . . . . . . . . . 16 N*m (145 in. lbs.)

Front Bolt . . . . . . . . . . . . . . 28 N*m (250 in. lbs.)

Rear Fitting . . . . . . . . . . . . 19 N*m (170 in. lbs.)

Special tools

Base brakes

Install Dust Boot 8248 Install Dust Boot 8248

Universal Handle C-4171 Universal Handle C-4171

    Dodge Durango (DN) 1998-2003 Service Manual

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