BLEEDING BRAKE SYSTEM
| WARNING | Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. |
| WARNING | Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. |
| CAUTION | Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. |
| CAUTION | Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. |
Note. When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after components have been correctly reconnected.
Note. If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article for brake bleeding procedure.
Note. The brakes should be bled whenever a brake line is disconnected.
BRAKELINE BLEEDING SEQUENCE
| Application | Sequence |
|---|---|
| If a hydraulic line is disconnected at the master cylinder. | Start at the brake caliper or wheel cylinder farthest from the brake master cylinder, and move to the next farthest brake caliper or wheel cylinder until all cylinders four cylinders have been bled. |
| If the disconnection point is anywhere except the master cylinder. | Start at the point closest to the disconnection, and move to the next closest brake caliper or wheel cylinder until all four have been bled. |
BRAKELINE BLEEDING SEQUENCE
BLEEDING BRAKES
- On level ground, jack up the vehicle and support it evenly on safety stands.
- Remove the bleeder cap and attach a vinyl tube to the bleeder screw. (Scheme 23)
- Place the other end of the vinyl tube in a clear container.
- The first person depresses the brake pedal a few times, and then holds it in the depressed position.
- The second person loosens the bleeder screw, drains out the fluid and closes the bleeder screw.
- Repeat steps 4 and 5 until no air bubbles are seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines.
- Inspect for correct brake operation.
- Verify that there is no fluid leakage. Wipe off any spilled fluid immediately.
- After bleeding the brakes, add brake fluid to the maximum level.
Scheme 23
BRAKE PEDAL FREE PLAY
With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS table. Adjust play by loosening push rod "C" and lock nut "D". (Scheme 24) Turn push rod until correct free play is obtained. Tighten lock nut "D" to specification. See TORQUE SPECIFICATIONS.
| Application | In. (mm) |
|---|---|
| Brake Pedal Free Play | 0-0.1 (0-3) |
BRAKE PEDAL FREE PLAY SPECIFICATIONS
Scheme 24
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
| CAUTION | If the brake switch is removed from the brake pedal, its proper functioning after being reinstalled cannot be guaranteed. Therefore, if the brake switch is removed, it must be replaced with a new one. When the brake switch connector is connected to the brake switch, the clearance with the pedal stopper is adjusted automatically. However, this mechanism will only function one time. |
- Verify that distance from center of upper surface of pedal pad to carpet is as specified. See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-164523-S21168392692004080900000) table. If not as specified, adjust brake pedal height. Loosen lock nut "B", and turn adjusting bolt "A" until it does not contact brake pedal. (Scheme 24)
- Loosen lock nut "D", and turn rod "C" to adjust pedal height. Tighten the bolt with lock nut "B". Tighten to specification.
- After adjustment, inspect the pedal play and the brake light operation. NOTE: The new brake switch projection height is adjusted automatically.
| Application | In. (mm) |
|---|---|
| Pedal Released | 7.36 (187) |
| Pedal Applied (1) | 2.7 (68) |
| (1) Minimum height with force of 132 lbs. (179 N.m). | |
| (1) | Minimum height with force of 132 lbs. (179 N.m). |
BRAKE PEDAL HEIGHT SPECIFICATIONS
PARKING BRAKE
- Pull the parking brake lever a few times. Depress brake pedal several times.
- Pull parking brake lever with a force of 22 lbs. Stroke should be 3-6 notches. If stroke is as specified, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking brake lever.
- Start the engine and depress the brake pedal several times. Stop the engine.
- Remove the ashtray behind the console. Turn the adjusting nut as shown in the illustration. (Scheme 25) After adjustment, turn the ignition switch to ON, pull the parking brake lever one notch, and verify that the parking brake warning light illuminates. Then verify that the rear brakes do not drag.
Scheme 25
POWER BRAKE UNIT
- With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal does not move as specified, go to next step.
- Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary, and go to next step.
- Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains at same height, power brake unit is operating. If pedal height recedes, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.
PROPORTIONING VALVE
- Connect 2 pressure gauges and adapters to dual proportioning valve. One to input port and other to output port. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000) . Depress brake pedal until pressure gauge reads as specified and check output pressure. See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-164523-S09748464052004080900000) table.
- Depress brake pedal again, applying additional pressure. Recheck output pressure. If output pressure is not as specified, replace dual proportioning valve.
| Application | Inlet Pressure - psi (kg/cm 2 ) | Outlet Pressure - psi (kg/cm 2 ) |
|---|---|---|
| Master Cylinder Pressure | 355 (25) | 326-384 (23-27) |
| 853 (60) | 461-549 (32.538.5) | |
PROPORTIONING VALVE PRESSURE SPECIFICATIONS
BRAKE PEDAL
| CAUTION | If the brake switch is removed from the brake pedal, its proper functioning after being reinstalled cannot be guaranteed. Therefore, if the brake switch is removed, it must be replaced with a new one. |
Note. When the brake switch connector is connected to the brake switch, the clearance with the pedal stopper is adjusted automatically. However, this mechanism will only function one time.
REAR AXLE BEARING & OIL SEAL
Note. For information on models with sealed wheel bearings, see appropriate REAR article in SUSPENSION.
REAR BRAKE CALIPER
Note. Brake rotor is also referred to as disc plate.
MASTER CYLINDER
| CAUTION | If the master cylinder body is damaged, replace the unit as a component. When securing the master cylinder in a vise, tighten only the flange of the master cylinder. |
2003
See BRAKES in SPECIFICATIONS under SPECIFICATIONS INDEX .
2004
| Application | Ft. Lbs. (N.m) |
|---|---|
| Brake Hose Caliper Mounting Bolt | 16-21 (22-29) |
| Brake Lever Bracket Mounting Bolts | 13.8-18.8 (18.6-25.5) |
| Brake Line Bracket Mounting Bolts | 13.7-18.8 (18.5-25.5) |
| Brake Pedal Lock Nut "D" | 11.6-15.9 (15.7-21.6) |
| Brake Pedal Mounting Nuts & Bolts | 13.8-18.8 (18.6-25.5) |
| Front Caliper Guide Bolts | 36.2-39.7 (49-53.9) |
| Front Caliper Mounting Bolts | 57.82-75.19 (78.4-101.9) |
| Rear Caliper Guide Bolt | 27.6-36.1 (37.3-49.0) |
| Rear Caliper Mounting Bolts | 37.1-49.1 (51.0-66.7) |
| Wheel Lug Nuts | 65-87 (88-118) |
| INCH Lbs. (N.m) | |
| Adjustment Gauge Nuts | 87-141 (9.8-16.0) |
| Bleeder Screw Front | 62-86 (6.9-9.8) |
| Bleeder Screw Rear | 53-77 (5.9-8.8) |
| Brake Line Fittings | 114-191 (12.8-21.6) |
| Brake Pedal Lock Nut "B" | 116-130 (9.8-14.7) |
| Master Cylinder Mounting Nuts | 87-141 (9.9-16.0) |
| Master Cylinder Stop Pin | 62-86 (6.9-9.8) |
| Master Cylinder Stop Screw | 18-21 (2.0-2.4) |
| Rotor Retaining Screw | 87-130 (9.8-14.7) |
DISC BRAKE TORQUE SPECIFICATIONS
See under BRAKES in SPECIFICATIONS under SPECIFICATIONS INDEX .
| Application | In. (mm) | |
|---|---|---|
| Front Rotor | ||
| Original Thickness | (1) | |
| Minimum Refinish Thickness | .94 (23.8) | |
| Minimum Thickness | .91 (23) | |
| Minimum Pad Thickness | .079 (2.0) | |
| Runout | .0008 (.02) | |
| Rear Rotor | ||
| Original Thickness | (1) | |
| Minimum Refinish Thickness | .35 (8.8) | |
| Minimum Thickness | .31 (8) | |
| Minimum Pad Thickness | .079 (2.0) | |
| Runout | .0008 (.02) | |
| (1) Information is not available from manufacturer. | ||
| (1) | Information is not available from manufacturer. |
DISC BRAKE SPECIFICATIONS