wheel CHEVROLET DYNASTY 1993 Workshop Manual

(3) Install washer and nut. Tighten nut to 27-34
N Im (240-300 in. lbs.) torque while rotating brake
drum. Then back off nut to completely release pre-
load. Finger tighten nut. (4) Position nut lock with one pair of slots in-line
with cotter pin hole. Install cotter pin. Clean and in-
stall grease cap. DISC BRAKE ASSEMBLY
(1) Position caliper support and spindle to axle. In-
stall the 4 spindle mounting bolts finger tight. Then
torque the 4 spindle mounting bolts to 75 N Im (55 ft.
lbs.) torque. (2) Install hub and bearings. (3) Install washer and nut. Tighten to 27-34 N
Im
(240-300 in. lbs.) torque while rotating hub. Then
back off nut to completely release preload. Finger
tighten nut. (4) Position nut lock with one pair of slots in-line
with cotter pin hole. Install cotter pin. Clean and in-
stall grease cap. (5) Install braking disc and adapter. Install caliper
assembly (see Rear Disc Brake) in Brakes Section,
Group 5. (6) Attach brake hose and parking brake cable to
caliper and suspension arm (Fig. 7). Install brake
hose mounting bracket to caliper support. (7) Route park brake cable through hanger bracket
and lock housing end into bracket. Install cable end
into (intermediate) connector (Fig. 7). (8) Install brake hose and fitting into bracket and
install lock. Attach brake tube assembly to hose fit-
ting and tighten to 16 N Im (140 in. lbs.) torque (Fig.
7). (9) Install wheel and tire assemblies and tighten
wheel stud nuts to 129 N Im (95 ft. lbs.) torque. Re-
move jacks and lower vehicle. (10) With suspension supporting vehicle, torque
lower shock absorber bolts to 61 N Im (45 ft. lbs.).
Then torque track bar bolt to 95 N Im (70 ft. lbs.).
(11) Bleed brake system. See BRAKES, Group 5.
Fig. 5 Install Springs and Isolators
Fig. 6 Install Shock Absorber and Track Bar Fasteners (Bolts)
Fig. 7 Reconnect Brake Tube and Park Brake Cable
2 - 58 SUSPENSION AND DRIVESHAFTS Ä

CONTROL MODULE
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove right side trunk trim panel.
(3) Remove electrical connectors from control mod-
ule and relay (Fig. 9). (4) Remove control module mounting screws and
remove assembly.
INSTALLATION
(1) Install relay on the control module mounting
bracket (if required). (2) Place control module in mounting position.
(3) Install mounting screws and tighten to 2-3 N Im
(19-29 in. lbs.). (4) Install control module and relay wiring connec-
tors (Fig. 9). (5) Install right side trunk trim panel.
(6) Connect negative battery cable.
COMPRESSOR RELAY
REMOVAL
(1) Remove right side trunk trim panel.
(2) Remove electrical connector from relay.
(3) Remove relay from control module mounting
bracket by prying out on locating clip (Fig. 10).
INSTALLATION
(1) Push relay onto bracket (relay will Lock into
position). (2) Install electrical connector.
(3) Install trim panel.
RIGHT SHOCK ABSORBER (WITH HEIGHT
SENSOR)
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle, see Hoisting, Group 0.
(3) Remove tire assembly.
(4) Disconnect height sensor connector, located on
right rear frame rail. (5) Remove both air lines connected to shock ab-
sorber ports. (6) Remove shock, see Shock Absorbers, Removal.
INSTALLATION
(1) Install shock assembly, see Shock Absorbers,
Installation. (2) Route height sensor wire through clip on shock
bracket, then tie strap to fuel filler tube. (3) Snap height sensor connector into underbody
harness connector. (4) Insert air lines.
(5) Install wheel/tire assembly.
Fig. 9 Control Module and Relay Wiring
Fig. 10 Control Module Connector
2 - 72 SUSPENSION AND DRIVESHAFTS Ä

(1) Remove dryer-to-compressor retaining screw
(Fig. 13). (2) Rotate dryer assembly 90É to release retaining
tangs from exhaust solenoid housing and withdraw
unit.
INSTALLATION
Inspect O-Ring for damage and location on dryer
assembly. (1) Insert and index air dryer locking tangs into
exhaust solenoid outlet. (2) Rotate air dryer assembly to lock position and
install air dryer-to-compressor retaining screw (Fig.
13).
SOLENOIDS (STRUTS AND AIR SPRINGS)
Front struts and rear springs are equipped with so-
lenoids that control air pressure and volume within
the assemblies. The solenoids are electrically oper-
ated to allow air input, contain air, or release air
pressure, depending on control module commands.
REMOVAL
WARNING: DO NOT ATTEMPT TO REMOVE OR IN-
STALL SOLENOIDS WHILE AIR SUSPENSION
(FRONT STRUTS AND REAR AIR SPRINGS) ARE
SUPPORTING VEHICLE.
Disconnect negative battery cable. Raise vehicle
and remove wheel and tire assembly then remove so-
lenoid(s) as follows: (1) Separate electrical connection to solenoid.
(2) Disconnect air line, see Air Lines and Fittings.
Solenoids have molded square tangs to fit into
stepped notches of the air spring housing. The
notches provide an air relief position and a retaining
position. The retaining position is locked with a re-
taining clip. (3) Remove retaining clip (Fig. 14). (4) Rotate solenoid to first step in housing and al-
low air pressure to vent (Fig. 15).
(5) Rotate solenoid to release slot and remove (Fig.
16).
Fig. 13 Air Dryer Remove/Install
Fig. 14 Remove Retaining Clips
Fig. 15 Release Air Pressure
Fig. 16 Remove Solenoid (Inspect O Ring)
2 - 86 SUSPENSION AND DRIVESHAFTS Ä

INSTALL
(1) Inspect O-Ring condition and position on sole-
noid stem. (O-Ring can become dislodged during re-
moval (Fig. 16). (2) Install solenoid with tangs to top ledge of hous-
ing and install retaining clip. (3) Reconnect air line and electrical connection.
STRUT (AIR SUSPENSION) DAMPERASSEMBLY
Service procedures for removal and installation for
(air or steel spring) assemblies are essentially the
same. Except for air venting/recharging and discon-
necting/connecting air lines and electrical connection.
REMOVAL (1) Disconnect battery negative cable.
(2) Hoist vehicle and remove wheel and tire assem-
bly. (3) See AIR LINES AND FITTINGS and discon-
nect air line. (4) Disconnect electrical leads, solenoid and height
sensors. (5) See SOLENOIDS (STRUT AND AIR SPRING)
and vent air spring and remove solenoids. (6) See STRUT DAMPER ASSEMBLY in FRONT
SUSPENSION and remove strut.
DISASSEMBLY/ASSEMBLE Disassembly is restricted to upper mount and bear-
ing housing. The strut shock absorber, air spring
with integral height sensor, solenoid and wiring har-
ness are serviced as an assembly. (1) Hold retaining plate locking washer and re-
move strut rod nut. (2) Remove locking washer, retainer plate, spacer,
flat washer and mount/bearing housing assembly
(Fig. 17). (3) Assemble in reverse order. Hold retainer plate
locking washer with suitable tool and tighten strut
rod nut to 75 N Im (55 ft. lbs.) torque.
INSTALLATION (1) See STRUT DAMPER ASSEMBLY in FRONT
SUSPENSION and install strut. (2) Install solenoid, see: SOLENOIDS (STRUT
AND AIR SPRINGS). (3) Connect electrical leads, solenoid and height
sensor. (4) Charge (inflate) air spring. See RECHARGE-
AIR SPRING to activate spring solenoid and air com-
pressor. Add air for 60 seconds.
RECHARGE AIR SPRING
To activate compressor; Ground Pin S08 to Pin
X20. To Activate Spring Solenoid:
² LF: Ground Pin S31 to X20 ²
RF: Ground Pin S30 to X20
² RR: Ground Pin S32 to X20
AIR SPRINGS REAR
REMOVAL
(1) Disconnect battery negative cable, hoist vehicle
and remove wheel and tire assembly. (2) See AIR LINES AND FITTINGS and discon-
nect air line and electrical connector from solenoid. (3) See SOLENOIDS (STRUT AND AIR SPRINGS)
and vent air from spring. Remove solenoid. (4) Release upper air spring alignment/retainer
clips. (Fig. 18) (5) Remove lower spring to axle nut (Fig. 19).
(6) Pry assembly down to pull alignment studs
through retaining clips (Fig. 20). Remove assembly.
INSTALLATION
(1) Position assembly lower stud into axle seat and
upper alignment pins through frame rail adaptor. (2) Install upper retaining clips.
(3) Install lower spring to axle nut: LOOSE AS-
SEMBLE. (4) Install solenoid and connect air line and electri-
cal connector. (5) Charge (inflate) air spring. See RECHARGING
AIR SPRING and add air for 60 seconds. (6) AFTER partial air recharge tighten lower nut
Fig. 17 Air Strut Upper Mount Assembly
Ä SUSPENSION AND DRIVESHAFTS 2 - 87

to 68 N Im (50 ft. lbs.) torque.
(7) Install wheel and tire assembly. Lower vehicle,
install wheel and tire assembly and connect battery
negative cable.
RIGHT SHOCK ABSORBER (WITH HEIGHT
SENSOR)
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle, see Hoisting, Group 0.
(3) Remove tire assembly.
(4) Disconnect height sensor connector located on
right rear frame rail. (5) Remove shock, see Shock Absorbers, Removal.
INSTALLATION
(1) Install shock assembly, see Shock Absorbers,
Installation. (2) Route height sensor wire through retaining
clips and then tie strap to fuel filler tube. (3) Snap height sensor connector into underbody
harness connector. (4) Install wheel/tire assembly.
(5) Height sensor wiring harness and white paint
mark on bottom shock eye must face to the front of
the vehicle (Fig. 21).
Fig. 18 Release Retaining Clips
Fig. 19 Remove/Install Lower Spring to Axle Nut
Fig. 20 Pry Assembly Out of Retaining Clips
Fig. 21 Right Rear Shock Absorber Installation
2 - 88 SUSPENSION AND DRIVESHAFTS Ä

REAR (STUB) AXLE ALIGNMENT ALL MODELS INDEX
page page
General Information ....................... 89 Rear Wheel Alignment..................... 89
GENERAL INFORMATION
Because front wheel drive vehicles are equipped with
rear suspension incorporating stub axles (or wheel
spindles). It is possible to align both the camber and toe
of the rear wheels.
REAR WHEEL ALIGNMENT
Alignment adjustment if required. Is made by adding
0.010 inch shims (from the service package kit) be-
tween the spindle mounting surface and axle mounting
plate. Each shim equals wheel change by .3É as shown
(for all car lines) in (Figs. 3 to 6). If rear wheel alignment is required, place vehicle on
alignment rack and check alignment specifications.
When recording rear toe-in (vehicle backed onto
alignment rack) REMEMBER to reverse sign
convention; a total toe-in on direct reading
charts is actually toe-out while driving. Maintain
rear alignment within Chrysler Motors recommenda-
tions, found in Specifications.
INSTALLATION OF REAR ALIGNMENT SHIMS
(1) Block front tires so vehicle will not move.
(2) Release parking brake.
(3) Hoist vehicle so that rear suspension is in full
rebound and tires are off the ground. See Hoisting in
Lubrication and Maintenance, Group 0. (4) Remove wheel and tire assembly.
(5) Pry off grease cap.
(6) Remove cotter pin and castle lock.
(7) Remove adjusting nut.
(8) Remove brake drum (Fig. 1). (9) Loosen four (4) brake assembly and spindle
mounting bolts enough to allow clearance for shim
installation (Fig. 2). Do not remove mounting
bolts.
(10) Install shims as shown in Figs. 3, 4, 5 and 6
for desired wheel change. No more than two shims
on each spindle should be used to bring alignment
within acceptable range. Wheel change by .3É per shim.
(11) Tighten down the 4 brake support plate and
spindle to axle mounting bolts until they are snug.
Then tighten the 4 bolts to the torque values listed
for the vehicle line which is being serviced.
² AA, AG, AJ, AP Bodies 75 N Im (55 ft. lbs.)
Fig. 2 Loosen Mounting Bolts
Fig. 3 Shim Installation for Toe-Out
Fig. 1 Remove Brake Drum
Ä SUSPENSION AND DRIVESHAFTS 2 - 89

² AC, AY Bodies 108 N Im (80 ft. lbs.)
(12) Install brake drum (Fig. 1).
(13) Install washer and nut. Tighten adjusting nut
to 27-34 N Im (240-300 in. lbs.) torque while rotating
wheel. Back off adjusting nut with wrench to com-
pletely release bearing preload. Finger tighten ad-
justing nut. (14) Position nut lock with one pair of slots in-line
with cotter pin hole. Install cotter pin. The end play
should be 0.025-0.076 mm (0.001-0.003 inch). Clean
and install grease cap. (15) Install wheel and tire assembly. Tighten
wheel nut to 129 N Im (95 ft. lbs.) torque.
(16) Lower vehicle.
(17) Check alignment specifications.
Fig. 4 Shim Installation for Toe-InFig. 5 Shim Installation for Positive Camber
Fig. 6 Shim Installation for Negative Camber
2 - 90 SUSPENSION AND DRIVESHAFTS Ä

BRAKES
CONTENTS
page page
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 10 AC/Y BODY ............. 72
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 6 AA,AG,AJ,AP BODY ....... 113
BRAKE DISC (ROTOR) ................... 53
BRAKE SUPPORT ASSEMBLY ............. 25
FRONT DISC BRAKES ................... 31
GENERAL INFORMATION .................. 1
HYDRAULIC SYSTEM CONTROL VALVES . . . 26
KELSEY HAYES DOUBLE PIN FAMILY CALIPER ............................ 35 KELSEY HAYES DOUBLE PIN NON-FAMILY
CALIPER ............................ 38
MASTER CYLINDER ..................... 66
PARKING BRAKES ...................... 57
POWER BRAKES ....................... 68
REAR DISC BRAKES .................... 45
REAR WHEEL DRUM BRAKES ............ 18
SERVICE ADJUSTMENTS .................. 4
WHEEL BEARINGS ...................... 70
WHEEL CYLINDERS ..................... 23
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the break down of these designa-
tions is included in the Introduction Section at the
front of this service manual. Standard brake equipment consists of:
² Double pin floating caliper disc front brakes.
² Rear automatic adjusting drum brakes.
² Differential valve with a brake warning switch.
² Master cylinder.
² Vacuum power booster.
² Double pin floating caliper rear disc brakes are
available on some models. The Bendix Anti-Lock 10 braking system, uses the
standard power brake system caliper assemblies,
braking discs, pedal assembly, brake lines and hoses.
The unique parts of the Bendix Anti-Lock 10 braking
system consists of the following components. Propor-
tioning valves, wheel speed sensors, tone wheels,
electronic control unit, modulator assembly and hy-
draulic assembly. These components replace the con-
ventional master cylinder and power booster. The
components will be described in detail in the Bendix
Anti-Lock 10 brake section in this group of the ser-
vice manual. The Bendix Anti-Lock 6 braking system, uses the
following standard brake system components. Master
cylinder, power booster, caliper assemblies, braking
discs, pedal assembly, brake lines and hoses. The
unique parts of the Bendix Anti-Lock 6 braking sys-
tem consists of the following components. Modulator
assembly, unique proportioning valves, wheel speed
sensors, tone wheels, and electronic control unit.
These components will be described in detail in the
Bendix Anti-Lock 6 brake section in this group of the
service manual. The front disc brake shoes have semi-metallic lin-
ings. The hydraulic brake system (Fig .123and4)is
diagonally split on both the Non-ABS and ABS brak-
ing system. With the left front and right rear brakes
on one hydraulic system and the right front and left
rear on the other. The Non-ABS and ABS brake system may use dif-
ferent types of brake line fittings and tubing flares.
The Non-ABS brake system uses double wall tubing
flares and fittings at all tubing joint locations. Some
ABS brake systems use both ISO style tubing flares
and double wall tubing flares and corresponding fit-
tings at different joint locations. See (Figs . 2 3 and 4)
for specific joint locations and type of tubing flare. The front disc brakes consist of two different types
of caliper assemblies. A double pin Kelsey-Hayes cal-
iper (family caliper) with a bolt-on adapter attached
to the steering knuckle. Or a double pin Kelsey-
Hayes caliper (non-family caliper) which mounts di-
rectly to rails on the steering knuckle. The non-
family caliper is only used on the AY Body
(Imperials).
CAUTION: Caliper pistons, boots and seals for the
different caliper assemblies used on the front and
rear disc brake assemblies are not interchangeable.
Misusage could result in a complete brake system
failure. Be sure that the parts are replaced with the
correct replacement parts, refer to the parts book
for the type and model year of the vehicle being
worked on.
The master cylinder is anodized, lightweight alu-
minum, with a bore size of 24.0mm, 21.0mm or 7/8
inch.
Ä BRAKES 5 - 1

SERVICE ADJUSTMENTS INDEX
page page
Adjusting Rear Service Brakes ............... 4
Bleeding Brake System ..................... 6
Brake Hose and Tubing ................... 11
Master Cylinder Fluid Level .................. 4 Stop Lamp Switch Adjustment (All Vehicles)
.... 13
Test for Fluid Contamination ................. 7
Testing Application Adjuster Operation ......... 6
Wheel Stud Nut Tightening .................. 7
MASTER CYLINDER FLUID LEVEL
ALL EXCEPT AC/AY BODY WITH ABS
Check master cylinder reservoir brake fluid level a
minimum of twice a year. Master cylinder reservoirs are marked with the
words fill to bottom of rings indicating proper fluid
level (Fig. 1). If necessary, add fluid to bring the level to the bot-
tom of the primary reservoir split ring. Use only Mopar tbrake fluid or an equivalent from
a sealed container. Brake fluid must conform to DOT
3, specifications. DO NOT use brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking. Use only brake fluid that was stored in a tightly-
sealed container. DO NOT use petroleum-based fluid because seal
damage in the brake system will result.
AC AND AY BODY WITH ANTI-LOCK BRAKES
The hydraulic assembly is equipped with a plastic
fluid reservoir with a filter/strainer in the filler neck
of the reservoir. The Anti-Lock brake system requires that the hy-
draulic accumulator be de-pressurized whenever
checking the brake fluid level. To check the brake
fluid level, the following procedure should be used: (1) With the ignition switch turned to the off position
and key removed. De-pressurize hydraulic accumula-
tor by applying brake pedal approximately 40 times,
using a pedal force of approximately 220 N (50 lbs.). A
noticeable change in pedal feel will occur when accu-
mulator is de-pressurized. Continue to apply brake
pedal several times after this change in pedal feel
occurs to insure that brake system is fully de-
pressurized. (2) Thoroughly clean both reservoir caps and sur-
rounding area of reservoir, (Fig. 2) before removing
caps. This is to avoid getting dirt into the reservoir and
contaminating the brake fluid. (3) Inspect the brake fluid to see if it is at the proper
level, see instructions on top of reservoir. (FILL TO
TOP OF WHITE SCREEN ON FRONT
FILTER/STRAINER.) (4) Fill reservoir with brake fluid to top of screen
(Fig. 3) on the filter/strainer located in brake fluid
reservoir. Only use brake fluid conforming to DOT 3
specifications such as Mopar tor equivalent.
(5) Replace brake fluid reservoir caps.
ADJUSTING REAR SERVICE BRAKES
Normally, self adjusting drum brakes will not
require manual brake shoe adjustment. Al-
though in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time. (1) Raise the vehicle so all wheels are free to turn.
See Hoisting Recommendations in the Lubrication And
Maintenance Section, at the front of this service
manual. (2) Remove rear brake adjusting hole rubber plug
(Fig. 4), from the rear brake shoe support plate. (3) Be sure parking brake lever is fully re-
leased. Then back off parking brake cable adjust-
ment so there is slack in the cable. (4) Insert Brake Adjuster, Special Tool C-3784, (Fig.
5) or equivalent through the adjusting hole in support
plate and against star wheel of adjusting screw. Move
handle of tool upward until a slight drag is felt when
the road wheel is rotated. (5) Insert a thin screwdriver or piece of welding rod
into brake adjusting hole (Fig. 5). Push adjusting lever
out of engagement with star wheel. Care
Fig. 1 Master Cylinder Fluid Level (All Except AC/AY
Body W/ABS)
5 - 4 BRAKES Ä

should be taken so as not to bend adjusting lever
or distort lever spring. While holding adjusting
lever out of engagement with star wheel, back off star
wheel to ensure a free wheel with no brake shoe drag. (6) Repeat above adjustment at the other rear wheel.
Install adjusting hole rubber plugs (Fig. 4) in rear
brake supports. (7) Adjust parking brake
afterwheel brake adjust-
ment. See parking brake adjustment, under Parking
Brakes in this group of the service manual. It is important to follow the above sequence to
avoid the possibility of the parking brake system
causing brake drag. This could occur if the park-
ing brakes are adjusted before the service
brakes.
Fig. 4 Brake Adjusting Hole Plug
Fig. 2 Master Cylinder Fluid Level (W/ABS)
Fig. 3 ABS Reservoir Fill Level On Filter/Strainer
Ä BRAKES 5 - 5