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Dodge Dakota (R1). Manual - part 233

SPECIFICATIONS

BASE BRAKES

SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Disc Brake Caliper
Type

Sliding

Disc Brake Caliper
Bore

70 mm (2.75 in.)

Disc Brake Rotor
Type

Ventilated

Disc Brake Rotor
Size

287 x 24 mm (11.3 x
0.944 in.)

Disc Brake Rotor
Max. Runout

0.102 mm (0.004)

Disc Brake Rotor
Max. Thickness Varaition

0.013 mm (0.0005 in.)

DESCRIPTION

SPECIFICATION

Disc Brake Rotor
Min.Rotor Thickness

22.6 mm (0.8898 in.)

Drum Brake
Size

228.6 x 63.5 mm (9 x
2.50 in

Drum Brake
Size

279 x 57 mm (11 x 2.25
in.)

Drum Brake
Max. Runout

0.20 mm (0.008 in.)

Drum Brake
Max. Diameter Variation

0.076 mm (0.003 in.)

Brake Booster
Type

Tandem Diaphragm

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Brake Booster

Mounting Nuts

—

250

Master Cylinder

Mounting Nuts

—

160

Caliper

Mounting Pins

—

Wheel Cylinder Bolts

1/4-20

—

Wheel Cylinder Bolts

5/16-18

—

Support Plate

Mounting Bolts/Nuts

—

Brake Line Fittings

Master Cylinder

—

170

Brake Line Fittings
Combination Valve

—

170

Brake Line Fittings

Wheel Cylinder

—

145

Brake Hose

Front Fitting

—

145

Brake Hose

Front Bolt

—

250

Brake Hose

Rear Fitting

—

170

5 - 8

BRAKES - BASE

SPECIAL TOOLS

BASE BRAKES

RED BRAKE WARNING
INDICATOR SWITCH

DESCRIPTION

A red warning lamp is used for the service brake

portion of the hydraulic system. The lamp is located
in the instrument cluster.

OPERATION

The red warning light alerts the driver if a pres-

sure differential exists between the front and rear
hydraulic systems or the parking brakes are applied.
The lamp is turned on momentarily when the igni-

tion switch is turn to the on position. This is a self
test to verify the lamp is operational.

HYDRAULIC/MECHANICAL

DESCRIPTION

The calipers are a single piston type. The calipers

are free to slide laterally, this allows continuous com-
pensation for lining wear.

OPERATION

When the brakes are applied fluid pressure is

exerted against the caliper piston. The fluid pressure
is exerted equally and in all directions. This means
pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 6).

Fluid pressure applied to the piston is transmitted

directly to the inboard brake shoe. This forces the
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within
the piston bore forces the caliper to slide inward on
the mounting bolts. This action brings the outboard
brake shoe lining into contact with the outer surface
of the disc brake rotor.

Install Dust Boot 8248

Universal Handle C-4171

Fig. 6 Brake Caliper Operation

1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE

BRAKES - BASE

5 - 9

In summary, fluid pressure acting simultaneously

on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will attempt to stop the rotors from turning and
bring the vehicle to a stop.

Application and release of the brake pedal gener-

ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake shoes do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor
surface clear each revolution.

The caliper piston seal controls the amount of pis-

ton extension needed to compensate for normal lining
wear.

During brake application, the seal is deflected out-

ward by fluid pressure and piston movement (Fig. 7).
When the brakes (and fluid pressure) are released,
the seal relaxes and retracts the piston.

The amount of piston retraction is determined by

the amount of seal deflection. Generally the amount
is just enough to maintain contact between the pis-
ton and inboard brake shoe.

BRAKE LINES

DESCRIPTION

Flexible rubber hose is used at both front brakes

and at the rear axle junction block. Double walled
steel tubing is used to connect the master cylinder to
the major hydraulic braking components and then to
the flexible rubber hoses. Double inverted style and
ISO style flares are used on the brake lines.

OPERATION

The hoses and lines transmit the brake fluid

hydraulic pressure to the calipers and or wheel cyl-
inders.

DIAGNOSIS AND TESTING - BRAKE LINE AND
HOSES

Flexible rubber hose is used at both front brakes

and at the rear axle junction block. Inspect the hoses
whenever the brake system is serviced, at every
engine oil change, or whenever the vehicle is in for
service.

Inspect the hoses for surface cracking, scuffing, or

worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.

Also check brake hose installation. Faulty installa-

tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.

The steel brake lines should be inspected periodi-

cally for evidence of corrosion, twists, kinks, leaks, or
other damage. Heavily corroded lines will eventually
rust through causing leaks. In any case, corroded or
damaged brake lines should be replaced.

Factory replacement brake lines and hoses are rec-

ommended to ensure quality, correct length and supe-
rior fatigue life. Care should be taken to make sure
that brake line and hose mating surfaces are clean
and free from nicks and burrs. Also remember that
right and left brake hoses are not interchangeable.

Use new copper seal washers at all caliper connec-

tions. Be sure brake line connections are properly
made (not cross threaded) and tightened to recom-
mended torque.

BRAKE PADS/SHOES

REMOVAL

(1) Clean master cylinder reservoir and filler caps.
(2) Remove reservoir filler cap and drain approxi-

mately 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) With a screw driver pry up on the caliper

spring and pull the spring out of the caliper holes.

(7) Remove caliper slide pins.
(8) Remove caliper, (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) and brake shoes (Fig. 8).

Fig. 7 Lining Wear Compensation By Piston Seal

1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON

5 - 10

BRAKES - BASE

HYDRAULIC/MECHANICAL (Continued)

(9) Remove outboard brake shoe (Fig. 9). Pry one

end of shoe retainer spring away from caliper. Then
tilt shoe upward and rotate it out of caliper.

(10) Remove inboard shoe by tilting shoe outward

until retainer spring is clear of caliper piston (Fig.
10).

(11) Support caliper with wire from suspension

component. Do not allow brake hose to support cali-
per weight.

INSTALLATION

(1) Clean slide surfaces of adapter ledges with a

wire brush. Then lubricate surfaces with a thin coat
of high temperature grease.

(2) Install new slide pin bushings if necessary.

(3) Install inboard shoe. Be sure retainer spring is

firmly seated in caliper piston.

(4) Insert outboard brake shoe in caliper (Fig. 11).

(5) Insure the outboard shoe retainer spring are

seated in the caliper (Fig. 12).

(6) Install caliper, (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION) and brake shoes over rotor and
into adapter.

(7) 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.

(8) Install caliper spring into one caliper hole and

under the adapter. Pull down on the opposite end of

Fig. 10 Inboard Brake Shoe

1 - CALIPER PISTON
2 - RETAINER SPRING
3 - INBOARD SHOE

Fig. 11 Installing Outboard Shoe

1 - CALIPER
2 - OUTBOARD SHOE

Fig. 8 Removing Caliper Assembly

1 - CALIPER AND BRAKE SHOES

Fig. 9 Outboard Brake Shoe

1 - SHOE SPRING
2 - OUTBOARD SHOE

BRAKES - BASE

5 - 11

BRAKE PADS/SHOES (Continued)

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