Dodge ZB 2005, Service Manual

Page: 127 / 1873

INSTALLATION - BRAKE ROTOR (REAR) . . . 35
SPECIFICATIONS
BRAKE ROTOR LIMITS/SPECIFICATIONS . . . 36
PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STANDARD PROCEDURE
STANDARD PROCEDURE - AUTOMATIC
ADJUSTER LOCKING OUT . . . . . . . . . . . . . . 37
STANDARD PROCEDURE - AUTOMATIC
ADJUSTER UNLOCKING . . . . . . . . . . . . . . . . 37
CABLE - PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
CALIPER - PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 41
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
LEVER - PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
PADS/SHOES - PARKING BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKES - BASE
DESCRIPTION - BASE BRAKE SYSTEM
The base brake system consists of the following
components:
•
Pedal assembly (Adjustable - Brake, Clutch, and
Accelerator)
•
Master cylinder
•
Power brake booster
•
Brake tubes and hoses
•
Disc brakes (front and rear)
•
Brake lamp switch
•
Parking brake
The adjustable pedal assembly includes all three
pedals and is power adjustable by a switch located
below the steering column.
All brakes are power assist type through the use of
a vacuum operated power brake booster.
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear disc
brakes.
The parking brake on this vehicle is hand lever
operated and has disc brake calipers dedicated to
parking brake only.
For more information on the description of any
individual base brake component, refer to that com-
ponent elsewhere in this section. For information on
the brake lamp switch, (Refer to 8 - ELECTRICAL/
ELECTRONIC
CONTROL MODULES/CONTROL-
LER ANTILOCK BRAKE - DESCRIPTION).
This vehicle is equipped with antilock brakes as
standard equipment. For information on the antilock
brake system (ABS) and its components, (Refer to 5 -
BRAKES - ABS - DESCRIPTION).
WARNINGS AND CAUTIONS
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET
BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE
CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS
WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION: During service procedures, grease and
any other foreign material must be kept off the cal-
iper assembly, surfaces of the brake rotor and
external surfaces of the hub. Avoid deformation,
scratching or nicking of the brake rotor and brake
shoe linings.
CAUTION: Use only Mopar
T
brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
conforming to DOT 4 specifications is recom-
mended. Brake fluid conforming to DOT 3 can be
used in absence of DOT 4. However, DOT 3 brake
fluid generally has a lower boiling point than DOT 4,
and is not recommended for high performance
applications. Brake fluid with less than DOT 3 spec-
ifications must not be used.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surface,
wash it off immediately with water.
5 - 2 BRAKES - BASE
ZB