Dodge Durango (DN) 1998-2003 Service Manual » Brakes » Base brake system »

Service procedures

Brake fluid level

Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid.

The fluid fill level is indicated on the side of the master cylinder reservoir (Fig. 9).

The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level.

Fig. 9 Master Cylinder Fluid Level - Typical

1 - INDICATOR

2 - RESERVOIR

Master cylinder bleeding

A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons.

Bleed tubes can be fabricated from brake line.

BLEEDING PROCEDURE

(1) Mount master cylinder in vise.

(2) Attach bleed tubes to cylinder outlet ports.

Then position each tube end into the reservoir (Fig.

10).

(3) Fill reservoir with fresh brake fluid.

(4) Press cylinder pistons inward with wood dowel.

Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid.

Fig. 10 Master Cylinder Bleeding

1 - BLEEDING TUBES

2 - RESERVOIR

Base brake bleeding

Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times.

Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary.

Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed.

Bleed only one brake component at a time in the following sequence:

Master Cylinder
Combination Valve
Rear Antilock Valve
Right Rear Wheel
Left Rear Wheel
Right Front Wheel
Left Front Wheel

MANUAL BLEEDING

(1) Remove reservoir filler caps and fill reservoir.

(2) If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.

Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding.

(3) Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid (Fig. 11). Be sure end of bleed hose is immersed in fluid.

Fig. 11 Bleed Hose Setup

1 - BLEED HOSE

2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID

(4) Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel.

PRESSURE BLEEDING

Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding.

Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding.

Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921.

Disc rotor machining

The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the lathe. Equipment capable of machining only one side at a time may produce a tapered rotor.

NOTE: A hub mounted on-vehicle lathe is recommended.

This type of lathe trues the rotor to the vehicles hub/bearing.

CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced.

Brake drum machining

The brake drums can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.025 to 0.038 mm (0.001 to 0.0015 in.) are recommended and will generally provide the best surface finish.

Be sure the drum is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks.

The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge.

CAUTION: Replace the drum if machining will cause the drum to exceed the maximum allowable diameter.

Brake tube flaring

A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available.

Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare (Fig. 12).

DOUBLE INVERTED FLARING

(1) Cut off damaged tube with Tubing Cutter.

(2) Ream cut edges of tubing to ensure proper flare.

(3) Install replacement tube nut on the tube.

(4) Insert tube in flaring tool.

(5) Place gauge form over the end of the tube.

(6) Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter.

(7) Tighten the tool bar on the tube (8) Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc (Fig. 13).

Fig. 12 Inverted Flare And ISO Flare