Dodge Durango

 Service Manual

Brakes » Four wheel antilock brakes
Removal and installation

Controller antilock brakes

NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Group 3 Differential and Driveline. For tire revolutions per mile refer to Group 22 Tire and Wheels. To program the CAB refer to the Chassis Diagnostic Manual.

REMOVAL

(1) Disconnect battery negative cable.

(2) Push the harness connector locks to release the locks, (Fig. 5) then remove the connectors from the CAB.

(3) Disconnect the pump motor connector (Fig. 6).

(4) Remove screws attaching CAB to the HCU (Fig. 7).

(5) Remove the CAB.

INSTALLATION

(1) Place the CAB onto the HCU.

NOTE: Insure the CAB seal is in position before installation.

(2) Install the mounting screws and tighten to 4-4.7 N*m (36-42 in. lbs.).

(3) Connect the pump motor harness.

(4) Connect the harnesses to the CAB and lock the connectors.

(5) Connect battery.

Fig. 5 Harness Connector Locks

1 - CONNECTOR LOCK

2 - CAB

Fig. 6 Pump Motor Connector

1 - PUMP MOTOR

2 - PUMP CONNECTOR

Antilock control assembly

NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Group 3 Differential and Driveline. For tire revolutions per mile refer to Group 22 Tire and Wheels. To program the CAB refer to the Chassis Diagnostic Manual.

Fig. 7 Controller Mounting Screws

1 - CAB

2 - MOUNTING LOCATIONS

REMOVAL

(1) Disconnect battery negative cable.

(2) Remove the brake lines from HCU (Fig. 8).

(3) Push the harness connector locks to release the locks, (Fig. 5) then remove the connectors from the CAB.

(4) Remove the nuts which attaches the assembly to the mounting bracket (Fig. 9).

(5) Remove the assembly from the vehicle.

Fig. 8 HCU Brake Lines

1 - CAB

2 - BRAKE LINES

3 - HCU

Fig. 9 Mounting Bracket

1 - ANTILOCK CONTROL ASSEMBLY

2 - MOUNTING BRACKET

INSTALLATION

(1) Install the antilock assembly into the bracket and tighten bolts to 14-15 N*m (10-12 ft. lbs.).

(2) Connect the CAB harnesses.

(3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 N*m (170 in. lbs.).

(4) Connect battery.

(5) Bleed brake system.

Front wheel speed sensor - 4x2

CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement part. Do not use substitute bolts under any circumstances.

REMOVAL

(1) Raise and support vehicle.

(2) Remove bolt attaching sensor to the steering knuckle (Fig. 10).

(3) Remove clamps securing sensor wire to control arm and inner fender panel.

(4) In engine compartment, disconnect sensor wire from harness and remove sensor.

INSTALLATION

(1) Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 N*m (190 in.

lbs.).

(2) Secure sensor wire retaining clamps to control arm and fender panel.

(3) In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components.

(4) Turn steering wheel back and forth to verify that wire is clear of steering and suspension components.

(5) Remove supports and lower vehicle.

Fig. 10 Front Wheel Speed Sensor - 4x2

1 - WHEEL SPEED SENSOR

2 - KNUCKLE

3 - MOUNTING BOLT

Front wheel speed sensor - 4x4

CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement bolts. Do not use substitute bolt under any circumstances.

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove brake caliper and rotor.

(4) Remove bolts attaching sensor to hub/bearing (Fig. 11).

(5) Remove clamps securing sensor wire to control arm and inner fender panel.

(6) In engine compartment, disconnect sensor wire and remove sensor.

INSTALLATION

(1) Guide sensor wire around upper control arm.

(2) Position sensor on hub/bearing and install attaching bolts. Tighten bolt to 18-25 N*m (160-220 in. lbs.).

Fig. 11 Front Wheel Speed Sensor - 4x4

1 - WHEEL SPEED SENSOR

2 - HUB/BEARING

3 - MOUNTING BOLTS

(3) Secure sensor wire retaining clamps to control arm and fender panel with original hardware.

(4) In engine compartment, connect sensor wire to harness connector. Insure wire is routed away from hot or rotating underhood components.

(5) Install brake rotor and caliper.

(6) Install wheel and tire assembly.

(7) Turn steering wheel back and forth to verify that wire is clear of steering and suspension components.

(8) Remove supports and lower vehicle.

TONE WHEEL

The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models (Fig. 12).

On 4-wheel drive models, the tone wheel is located in the hub/bearing housing.

The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Refer to Group 2 Suspension for the service procedure.

Rear wheel speed sensor

REMOVAL

(1) Raise vehicle on hoist.

(2) Remove brake line mounting nut and remove the brake line from the sensor stud.

(3) Remove mounting stud from the sensor and shield (Fig. 13).

(4) Remove sensor and shield from differential housing.

(5) Disconnect sensor wire harness and remove sensor.

Fig. 12 Tone Wheel 4x2

1 - HUB

2 - TONE WHEEL

3 - BEARING

Fig. 13 Rear Speed Sensor Mounting

1 - DIFFERENTIAL HOUSING

2 - WHEEL SPEED SENSOR

INSTALLATION

(1) Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector.

(2) Install O-ring on sensor (if removed).

(3) Insert sensor in differential housing.

(4) Install sensor shield.

(5) Install the sensor mounting stud and tighten to 24 N*m (200 in. lbs.).

(6) Install the brake line on the sensor stud and install the nut.

(7) Lower vehicle.

EXCITER RING

The exciter ring is mounted on the differential case. If the ring is damaged refer to Group 3 Differential and Driveline for service procedures.

Specifications

Torque chart

DESCRIPTION   TORQUE

ABS Assembly

Bracket bolts . . . . . . . . 14-15 N*m (10-12 ft. lbs.)

Mounting Nuts . . . . . . . . . . 12 N*m (102 in. lbs.)

CAB Screws . . . . . . . . . 4-4.7 N*m (36-42 in. lbs.)

Brake Line Fittings . . . . . . . 19 N*m (170 in. lbs.)

Wheel Speed Sensors

Front Sensor Bolt . . . . . . . . 21 N*m (190 in. lbs.)

Rear Sensor Bolt . . . . . . . 22.5 N.m (200 in. lbs.)