Dodge Durango

 Service Manual

Brakes » Base brake system » Removal and installation
Disc brake caliper

REMOVAL

(1) Clean master cylinder reservoir and filler caps.

(2) Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid.

(3) Raise and support vehicle.

(4) Remove front wheel and tire assemblies.

(5) Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe.

(6) Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged (Fig. 20).

Fig. 20 Caliper Brake Hose Connection

1 - CALIPER

2 - FRONT BRAKE HOSE

3 - FITTING WASHERS

(7) With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes.

(8) Remove caliper and brake shoes from caliper.

INSTALLATION

(1) Install brake shoes in caliper.

(2) Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges.

(3) Install and tighten caliper slide pins to 30 N*m (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins.

(4) Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring (Fig. 21) and hold the end under the adapter. With a scew driver pry up on the spring (Fig. 22) to seat the spring into the other caliper hole.

NOTE: Verify the spring is seated properly into the caliper holes.

Fig. 21 Caliper Spring

1 - CALIPER

2 - ADAPTER

3 - CALIPER SPRING

Fig. 22 Seat Caliper Spring

1 - SCREWDRIVER

2 - ADAPTER

3 - CALIPER

4 - ADAPTER

5 - CALIPER SPRING

(5) Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 N*m (18 ft.

lbs.).

CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt.

(6) Bleed base brake system.

(7) Install wheel and tire assemblies.

(8) Remove supports and lower vehicle.

(9) Pump brake pedal to seat brake shoes.

(10) Fill brake fluid reservoir.

(11) Verify firm pedal before moving vehicle.

Brake lamp switch

Brake pedal

Combination valve

Master cylinder

Power brake booster

Disc brake caliper

Disc brake shoes

Disc brake rotor

Rear brake shoes

Wheel cylinder

Brake support plate

Front park brake cable

Rear park brake cables

Park brake pedal assembly