Disc & Drum: Other Dodge Dakota Sport

BRAKE SYSTEM

All models are equipped with single piston, sliding caliper front disc brakes with ventilated cast iron rotors. Rear brakes are equipped with anti-lock drum brakes. System also includes a power brake booster, a dual reservoir master cylinder, wheel cylinders, brake lines, hoses and a combination valve. Combination valve consists of a metering valve and a pressure differential switch. Caravan, Town & Country and Voyager also include a height sensing proportioning valve.

The disc brake caliper is free to move laterally on adapter slide surfaces. On brake application, fluid pressure is exerted equally against caliper piston and all surfaces of caliper piston bore. Piston pressure is transmitted directly to inboard disc pad, which presses against disc rotor. Pressure applied to inboard pad makes the caliper slide inward. The inward movement presses the outboard pad against opposite side of disc rotor to complete braking action. On brake release, piston and caliper return to normal, non-applied position.

All models without full floating rear axle use 9", 10" or 11" single anchor rear brakes. All 3 sizes are of the same design. see scheme 14

All models with full floating rear axle use 12" single anchor rear brakes of slightly different design than 9", 10" and 11" brakes. see scheme 15

Note. For information on Anti-Lock Brake Systems (ABS), see the ANTI-LOCK BRAKE SYSTEM article.

VACUUM PUMP (DIESEL)

The vacuum pump provides for the brake booster. The vacuum pump and power steering is one assembly which is driven from a common shaft from the front gear train. To service either pump the complete assembly must be removed from the front gear housing. The operating range for vacuum pump is 25-8.5 in Hg. The vacuum is monitored by a vacuum sensor which is located under the left hood hinge in the engine compartment and vacuum is supplied by a hose teed off of the check valve in the brake booster.

Note. The sensor will activate the brake warning light on the warning light panel in 10 seconds or less when the vacuum drops to 8.5 in Hg. or less in the brake system.

Scheme 15

1. To prevent excessive amount of air from entering the brake system, creating poor brake operation, bleed master cylinder before installation.
2. Place master cylinder in soft-jawed vise. DO NOT tighten vise enough to damage master cylinder. Install bleeder tubes in both outlets of master cylinder. (Scheme 15)
3. Fill master cylinder with clean brake fluid that meets DOT 3 specifications. Ensure that the end of bleeder tubes are submerged in the brake fluid.
4. Using proper sized rod, apply and release master cylinder until no air bubbles exist in brake fluid flow. Once all air bubbles are gone from master cylinder, secure cap and install on vehicle.
5. Leave bleeder tubes installed on master cylinder until master cylinder is installed. Bleed brake system after installation.

MASTER CYLINDER (ON-VEHICLE BLEEDING)

1. After bench bleeding, install master cylinder on vehicle. Remove bleeder lines and install brake lines. DO NOT fully tighten brake lines at this time.
2. Slowly force brake pedal to the floor, and hold pedal in this position. Tighten brake lines and release brake pedal. Repeat procedure until no air bubbles exist at brake lines. Wheel cylinders and calipers may also require bleeding.

Dakota, Pickup, Ramcharger & RWD Van

1. Before using pressure tank bleeding procedure, correctly position the metering valve (incorporated in the combination valve) to allow brake fluid to flow through the valve to the entire brake system.
2. The valve stem may be retained in the metering valve during bleeding procedure, using Valve Retainer (C-4121). (Scheme 16) Remove valve retainer once brake bleeding procedure is complete.

Scheme 16

VACUUM BLEEDING

Fill master cylinder. Install vacuum bleed equipment to first bleeder valve to be serviced. Open bleeder valve 3/4-1 turn. Depress vacuum pump, and pull fluid into reservoir jar. Bleed each bleeder valve in sequence. See BLEEDING SEQUENCE TABLE .

PRESSURE BLEEDING

1. Clean master cylinder cap and surrounding area. Remove cap. With pressure tank at least 1/2 full, connect to master cylinder with adapters. Attach bleeder hose to first bleeder valve to be serviced. See the «BLEEDING SEQUENCE»(ref-44030-S36365786392001011500000) table.
2. Place other end of hose in clean glass jar partially filled with clean brake fluid so end of hose is submerged in fluid. The metering valve must be positioned properly before pressure bleeding. See «POSITIONING METERING VALVE BEFORE BLEEDING SYSTEM»(ref-44030-S11595782042001011500000) .
3. Open release valve on pressure bleeder. Follow equipment manufacturer's pressure instructions or see «PRESSURE BLEEDER SETTINGS»(ref-44030-S22007315712001011500000) table. Open bleeder screw 3/4-1 turn and note fluid flow.
4. Close bleeder screw when fluid flowing is free of bubbles. Repeat procedure on remaining wheels in proper sequence. Check brake pedal operation after bleeding has been completed.
5. Remove pressure bleeding equipment and valve retainer from metering valve. Ensure that master cylinder is full of fluid.

PRESSURE BLEEDER SETTINGS

MANUAL BLEEDING

Note. When bleeding disc brakes, air may tend to cling to caliper walls. Lightly tap caliper, while bleeding, to aid in removal of air.

1. Fill master cylinder. Install bleeder hose to first bleeder valve to be serviced. See «BLEEDING SEQUENCE»(ref-44030-S36365786392001011500000) table. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
2. Open bleeder valve 3/4-1 turn. Depress brake pedal slowly through full travel. Close bleeder valve and release pedal. Repeat procedure until flow of fluid shows no signs of air bubbles.

Note. When bleeding brake system manually, ensure bleeder valve is closed when brake pedal is released.

BLEEDING SEQUENCE

Before bleeding system, exhaust all vacuum from power unit by depressing brake pedal several times. Bleed master cylinder with bleeder screws (if equipped). Bleed slave cylinder on vehicles equipped with remote mount power assist units. Bleed wheel cylinders and calipers in sequence. See BLEEDING SEQUENCE table.

BLEEDING SEQUENCE

Caravan, Town & Country, & Voyager

1. Premature rear wheel skid may be caused by incorrect adjustment of the height sensing proportioning valve. Before making adjustment, inspect brake system and bleed entire system using appropriate method. See «BLEEDING PROCEDURES»(ref-44030-S39992817012001011500000).
2. Raise vehicle on hoist and allow rear suspension to hang free with rear wheels removed. Ensure hoist does not contact rear springs. Disconnect shock absorbers. Loosen adjustment nut on actuator assembly. (Scheme 17) Ensure actuator assembly hook is correctly seated on proportioning valve lever.
3. Pull actuator assembly toward spring hanger until proportioning valve lever bottoms. Hold proportioning valve lever in this position. Tighten adjustment nut to 25 INCH lbs. (2.8 N.m). Install shock absorbers and rear wheels.

Scheme 17

1. Remove actuator assembly adjustment nut. Disconnect actuator assembly hook from height sensing proportioning valve. Install one gauge and "T" of Height Sensing Proportioning Valve Test Set (C-4007-A) in either line of master cylinder outlet port between master cylinder and brake warning switch.
2. Install other gauge and "T" of test set in either line of proportioning valve outlet port between proportioning valve and rear wheel cylinder. Bleed brake system and gauges.
3. Have an assistant press and hold brake pedal. Note reading on both gauges. Pressure on inlet gauge (at master cylinder) should be 500 psi (35 kg/cm 2 ). Pressure on outlet gauge (at proportioning valve) should be 100-200 psi (7-14 kg/cm 2 ).
4. If pressures are not to specification, replace height sensing proportioning valve. If pressures are okay, remove test equipment. Install actuator and adjust height sensing proportioning valve. See «HEIGHT SENSING PROPORTIONING VALVE ADJUSTMENT»(ref-44030-S27488803972001011500000) . Bleed brake system.

Caravan, Dakota 4WD, Town & Country & Voyager)

Raise and support vehicle. Remove wheels. Remove brake caliper. Hang caliper with wire to support caliper weight. Remove rotor from drive flange. To install, reverse removal procedure.

Raise and support vehicle. Disconnect actuator assembly and brake lines from valve. Cap brake lines to prevent dirt from entering system. Remove screws securing valve and remove valve. Install new valve. Bleed brake system. See BLEEDING PROCEDURES . Adjust valve. Refer to HEIGHT SENSING PROPORTIONING VALVE ADJUSTMENT .

COMBINATION VALVE

Raise and support vehicle. Mark brake lines for assembly reference. Disconnect parking brake cable from clip on valve. Disconnect brake warning light connection at switch. Disconnect all brake hydraulic lines at valve. Cap brake lines to prevent dirt from entering system. Remove valve mounting bolts. Remove valve from vehicle. To install, reverse removal procedures. Bleed brake system. See BLEEDING PROCEDURES .

12" Drum

1. Raise and support vehicle. Remove wheel assembly. Remove axle shaft nuts, washers and cones. Using hammer, sharply strike center of axle flange to free cones. Remove axle shaft and gasket.
2. Remove nut lock. Remove adjustment nut and outer bearing. Carefully remove drum assembly. Remove seal and inner bearing from drum assembly.
3. Install inner bearing and seal in drum. Install drum assembly, outer bearing and adjustment nut. Tighten adjustment nut to 120-140 ft. lbs. (163-190 N.m) while rotating drum.
4. Back off adjustment nut approximately 1/3 turn (120 degrees) to obtain .001-.008" (0.03-0.20 mm) end play. Tap nut lock into spindle keyway. Install gasket and axle shaft. Install wheel assembly and lower vehicle.

DISC BRAKE SPECIFICATIONS (FWD VANS)

DAKOTA

DISC BRAKE SPECIFICATIONS (DAKOTA)

PICKUP

DISC BRAKE SPECIFICATIONS (PICKUP)

RAMCHARGER

DISC BRAKE SPECIFICATIONS (RAMCHARGER)

RWD VANS

DISC BRAKE SPECIFICATIONS (RWD VANS)