brake light CHEVROLET DYNASTY 1993 Service Manual

COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
BRAKES ..................................5-1
BENDIX ANTILOCK 4 BRAKE SYSTEM ...........5-12
ABS BRAKE SYSTEM DIAGNOSTIC FEATURES.......5-24
ABS SYSTEM SELF DIAGNOSIS................ 5-24
BENDIX ANTILOCK 4 BRAKE SYSTEM DIAGNOSTICS....5-25
CONTROLLER ANTILOCK BRAKE CAB............. 5-24
LATCHING VERSUS NON-LATCHING ABS FAULTS.......5-25
START-UP CYCLE........................ 5-24
ABS COMPUTER SYSTEM SERVICE PRECAUTIONS....5-23
ABS GENERAL SERVICE PRECAUTIONS........... 5-23
ABS BRAKE SYSTEM ON VEHICLE SERVICE.........5-23
TEST DRIVING ABS COMPLAINT VEHICLES.......... 5-23
WHEEL SPEED SENSOR CABLES............... 5-23
ANTILOCK BRAKE SYSTEM COMPONENTS..........5-16
BUILD/DECAY VALVES..................... 5-16
FLUID SUMPS.......................... 5-17
HYDRAULIC SPRING ACCUMULATOR.............5-17
MODULATOR ASSEMBLY.................... 5-16
PRESSURE DIFFERENTIAL SWITCH..............5-17
PROPORTIONING VALVES................... 5-17
PUMP/MOTOR ASSEMBLY...................5-17
SHUTTLE ORIFICE........................ 5-16
WHEEL SPEED SENSORS....................5-18
ANTILOCK BRAKE SYSTEM DEFINITIONS..........5-14
ANTILOCK BRAKES OPERATION AND PERFORMANCE. . . 5-15
ANTILOCK BRAKE SYSTEM OPERATION............ 5-15
PEDAL FEEL........................... 5-15
TIRE NOISE & MARKS.....................5-15
ANTILOCK SYSTEM RELAYS AND WARNING LAMPS. . . 5-19
ANTILOCK WARNING LAMP DIODE..............5-20
Antilock Warning Lamp Off................... 5-20
Antilock Warning Lamp On...................5-20
PUMP/MOTOR RELAY...................... 5-20
SYSTEM RELAY......................... 5-19
BENDIX ANTILOCK 4 BRAKE SYSTEM DIAGNOSTICS. . . 5-22
DEFINITIONS........................... 5-23
GENERAL INFORMATION....................5-22
BLEEDING BENDIX ANTILOCK 4 BRAKE SYSTEM......5-25
BENDIX ANTILOCK 4 MODULATOR ASSEMBLY BLEEDING
PROCEDURE
......................... 5-26
HYDRAULIC BRAKE TUBE ASSEMBLY (JUNCTION BLOCK
TO MODULATOR ASSEMBLY)
................ 5-34
INSTALL............................ 5-36
REMOVE............................5-34
MASTER CYLINDER AND POWER BOOSTER.........5-38
REMOVAL AND INSTALLATION................. 5-38
MODULATOR ASSEMBLY CIRCUIT BLEEDING PROCEDURE
AND SEQUENCE
....................... 5-26
1 MODULATOR PRIMARY CHECK VALVE CIRCUIT........5-26
2 MODULATOR SECONDARY CHECK VALVE CIRCUIT......5-26
3 MODULATOR ASSEMBLY PRIMARY SUMP CIRCUIT......5-27
4 MODULATOR ASSEMBLY PRIMARY ACCUMULATOR CIRCUIT. 5-27
5 MODULATOR ASSEMBLY SECONDARY SUMP CIRCUIT....5-28
6 MODULATOR ASSEMBLY SECONDARY ACCUMULATOR
CIRCUIT
........................... 5-29
MODULATOR ASSEMBLY (FIG. 1)...............5-30
INSTALL............................ 5-32
REMOVE............................5-30
PROPORTIONING VALVES (FIG. 1)...............5-38
INSTALL............................ 5-39
REMOVAL...........................5-38
PUMP/MOTOR SERVICE....................5-29
CONTROLLER ANTILOCK BRAKE CAB.............5-18
CONTROLLER ANTILOCK BRAKE (INPUTS)..........5-19
CONTROLLER ANTILOCK BRAKE (OUTPUTS).........5-19
DIAGNOSTIC CONNECTOR.................... 5-19
ELECTRONIC COMPONENTS..................5-41
CONTROLLER ANTILOCK BRAKE CAB.............5-41
INSTALL............................ 5-42
REMOVE............................5-41
FRONT WHEEL SPEED SENSOR (FIG. 9)...........5-43
INSTALLATION......................... 5-44
REMOVAL........................... 5-43
REAR WHEEL SPEED SENSOR (FIGS. 10 AND 11)......5-44
INSTALLATION......................... 5-44
REMOVAL........................... 5-44
REMOVAL/INSTALLATION OF SYSTEM RELAY.........5-42
INSTALL............................ 5-43
REMOVE............................5-43
REMOVE/INSTALL PUMP MOTOR RELAY...........5-43
WHEEL SPEED SENSORS.................... 5-43
INSPECTION.......................... 5-43
GENERAL INFORMATION....................5-12
HYDRAULIC CIRCUITS AND VALVE OPERATION......5-20
ABS BRAKING-BUILD PRESSURE............... 5-20
BUILD/DECAY VALVES..................... 5-20
ABS BRAKING-DECAY PRESSURE...............5-22
BUILD/DECAY VALVES..................... 5-22
NORMAL BRAKING....................... 5-20
BUILD/DECAY VALVES.....................5-20
MAJOR COMPONENTS...................... 5-14
CONTROLLER ANTILOCK BRAKE CAB.............5-14
MASTER CYLINDER AND VACUUM BOOSTER.........5-14
MODULATOR AND PUMP MOTOR/ASSEMBLY.........5-14
WHEEL SPEED SENSORS.................... 5-14
MECHANICAL DIAGNOSTICS AND SERVICE
PROCEDURES
.......................... 5-24
INTERMITTENT FAULTS.....................5-24
SPECIAL SERVICE TOOL....................5-24
DRB DIAGNOSTIC TESTER...................5-24
NORMAL BRAKE SYSTEM FUNCTION.............5-14
ON-CAR ABS BRAKE SYSTEM SERVICE...........5-25
CHECKING BRAKE FLUID LEVEL................ 5-25
GENERAL SERVICE PRECAUTIONS...............5-25
SPECIFICATIONS......................... 5-46
SYSTEM SELF-DIAGNOSTICS..................5-15
VEHICLE PERFORMANCE.................... 5-15
WARNING SYSTEMS OPERATION...............5-16
NORMAL OPERATION OF WARNING LAMP..........5-16
GENERAL INFORMATION .....................5-1
HYDRAULIC SYSTEM CONTROL VALVES .........5-10
GENERAL INFORMATION.................... 5-10
HYDRAULIC SYSTEM SERVICE PROCEDURES........5-11
BRAKE WARNING SYSTEM................... 5-11
CHECKING BRAKE WARNING SWITCH UNIT...........5-11
TESTING ANTILOCK PROPORTIONING VALVES........5-11
PRESSURE DIFFERENTIAL WARNING LIGHT SWITCH. . . 5-10
SERVICE ADJUSTMENTS .....................5-3

inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
BATTERY
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds. Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result. Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area. All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EXHAUST SYSTEM ISOLATOR AND HANGER
The exhaust system should be inspected when un-
der vehicle service is performed. The exhaust system
should not make contact with under body, brake ca-
bles, brake/fuel lines, fuel tank or suspension compo-
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo-
nents must be replaced. For proper service proce-
dures see Group 11, Exhaust System and Intake
Manifold.
Ä LUBRICATION AND MAINTENANCE 0 - 15

BRAKE RESERVOIR LEVEL INSPECTION
WARNING: DO NOT ALLOW PETROLEUM OR WATER
BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS-
TEM BEFORE ADDING BRAKE FLUID TO RESER-
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER-
SONAL INJURY.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal
for the reservoir level to drop as disc brake pads
wear. When fluid must be added, use Mopar, Brake
Fluid or equivalent. Use only brake fluid conforming
to DOT 3, Federal, Department of Transportation
specification. To avoid brake fluid contamination, use
fluid from a properly sealed container. On vehicles with anti-lock brakes, depressurize the
system before inspecting fluid level. Turn OFF the
ignition and remove the key. Pump the brake pedal
at least 50 times to relieve the pressure in the sys-
tem.
On all vehicles, if fluid should become low after sev-
eral thousand kilometers (miles), fill the reservoir to
level marks on the side of the reservoir (Fig. 8 or 9).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug-
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle
height change. For proper service procedures, refer to
Group 8L, Lamps. DRIVER SUPPLEMENTAL AIRBAG SYSTEM
If the AIRBAG indicator lamp does not light at all,
stays lit or lights momentarily or continuously while
driving, a malfunction may have occurred. Prompt service is required. Refer to Group 8M, Restraint
Systems for proper diagnostic procedures.
BODY LUBRICATION
Body mechanisms and linkages should be inspected,
cleaned and lubricated as required to maintain ease of
operation and to prevent corrosion and wear. Before a component is lubricated, oil, grease and dirt
should be wiped off. If necessary, use solvent to clean
component to be lubricated. After lubrication is com-
plete, wipe off excess grease or oil. During winter season, external lock cylinders should
be lubricated with Mopar, Lock Lubricant or equiva-
lent to ensure proper operation when exposed to water
and ice. To assure proper hood latching component operation,
use engine oil to lubricate the lock, safety catch and
hood hinges when other under hood service is per-
formed. Mopar, Multi-purpose Grease or equivalent
should be applied sparingly to all pivot and slide
contact areas.
USE ENGINE OIL ON:
² Door hingesÐHinge pin and pivot points.
² Hood hingesÐPivot points.
² Luggage compartment lid hingesÐPivot points.
USE MOPAR LUBRIPLATE OR EQUIVALENT ON:
² Door check straps.
² Hood counterbalance springs.
² Luggage compartment lid latches.
² Luggage compartment lid prop rod pivots.
² Ash tray slides.
² Fuel Fill Door latch mechanism.
² Park brake mechanism.
² Front seat tracks.
Fig. 8 Anti-lock Brake Reservoir
Fig. 9 Master Cylinder Brake ReservoirÐExcept
Anti-lock
0 - 22 LUBRICATION AND MAINTENANCE Ä

INSPECTION
Inspect for evidence of fluid running from the up-
per end of the reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage be-
tween the strut rod and strut shaft seal is not un-
usual and does not affect performance of the strut
assembly.
INSTALLATION
(1) Install unit into fender reinforcement and in-
stall retaining nuts and washer assemblies (Fig. 1).
Tighten the 3 nuts to 27 N Im (20 ft. lbs.) torque.
(2) Position steering knuckle neck into strut as-
sembly. Position washer plate and install cam and
knuckle bolts (Fig. 4). (3) Attach brake hose retainer to damper, tighten
the screw to 13 N Im (10 ft. lbs.) torque (Fig. 4).
(4) Index strut to original outline on the knuckle
neck, or align mark on cam bolt with the mark that
was put on the strut to steering knuckle bracket
(Fig. 4). (5) Plac e a 4 inch (or larger) C clamp on the strut
and knuckle as shown in (Fig. 5). Tighten the clamp
just enough to eliminate any looseness between the
knuckle and the strut. Check alignment of the index marks and tighten the bolts to 100 N
Im (75 ft. lbs.)
plus 1/4 turn beyond specified torque. Remove the
(C) clamp.
(6) Install wheel and tire assembly. Tighten the
wheel nuts to 129 N Im (95 ft. lbs.) torque.
DISASSEMBLY (STRUT DAMPER)
(1) Compress front coil spring with Spring Com-
pressor, Special Tool C-4838 (Fig. 6).
(2) Hold end of strut shaft from rotating with
wrench, while loosening strut shaft nut. Remove nut
from shaft (Fig. 7). (3) Remove the upper strut mount from the strut
assembly. (4) Remove coil spring from the strut assembly.
Mark spring for installation back on the same
side of the vehicle (Fig. 11).
CAUTION: see Suspension Coil Springs before re-
leasing coil from Tool C-4838.
(5) Inspect strut damper, mount assembly (Fig. 8)
for:
Fig. 4 Strut Damper Removal
Fig. 5 Strut Damper Installation
Fig. 6 Compressing Coil Spring
2 - 8 SUSPENSION AND DRIVESHAFTS Ä

to the road surface. While being able to twist as one
wheel moves vertically with respect to the other.Roll resistance is provided partly by the axle's re-
sistance to twist. But primarily by a torque tube or
rod (depending on the suspension option called for)
running through the channel and attached rigidly to
its end plates by welding. Because the torque tube/
rod is an integral part of the axle assembly, it cannot
be individually replaced. The spindles are bolted to the axle end (spindle
mounting) plates and can be individually replaced if
required. Rear wheel alignment changes require the
use of shims between the spindle and axle end plates.
SHOCK ABSORBERS
REMOVAL
(1) Raise vehicle, see Hoisting, Group 0.
(2) Support axle and remove wheel and tire assem-
bly. (3) If equipped with air shocks, disconnect air
lines. (4) Remove upper and lower shock absorber fasten-
ers, remove shock absorbers (Fig. 2).
INSPECTION
Inspect for evidence of fluid leakage from upper
end of reservoir. (Actual leakage will be a stream of
fluid running down and leaking off lower end). Slight
seepage is not unusual and will not effect perfor-
mance.
INSTALLATION
(1) Position shock absorber on car. Install upper
and lower fasteners loosely to hold shock absorber in
place. (2) Tighten upper fastener to 61 N Im (45 ft. lbs.)
torque. Connect air line, if so equipped. (3) Install wheel and tire assembly, tighten wheel
stud nuts to 129 N Im (95 ft. lbs.) torque. Lower vehi-
cle to ground. (4) With suspension supporting the weight of the
vehicle. Tighten lower shock absorber fastener to 54
N Im (40 ft. lbs.) torque.
COIL SPRINGS AND JOUNCE BUMPER
REMOVAL
(1) Lift vehicle see hoisting Group 0.
(2) Support axle assembly and remove both lower
shock absorber attaching bolts. (3) Lower axle assembly until spring and spring
upper isolator can be removed (Fig. 3). Do not
stretch brake hose. (4) Remove two screws holding cup to rail (Fig. 1).
Remove assembly.
INSTALLATION
(1) Position cup to rail. Install and tighten attach-
ing bolts to 8 N Im (70 in. lbs.) torque.
(2) Install isolator over jounce bumper and install
spring. (3) Raise axle and loosely assemble both shock ab-
sorber to axle mounting bolts. Remove axle support
and lower vehicle. (4) With suspension supporting the weight of the
vehicle. Tighten both shock absorber attaching bolts
to 61 N Im (45 ft. lbs.) torque.
Fig. 2 Remove/Install Shock Absorber Fasteners
Fig. 3 Coil Spring & Jounce Bumper
Ä SUSPENSION AND DRIVESHAFTS 2 - 51

WARNING: WHEN REMOVING THE REAR AXLE
PIVOT BUSHING ON VEHICLES EQUIPPED WITH EI-
THER REAR COIL SPRINGS OR AIR SUSPENSION.
THE REAR AXLE MUST BE SUPPORTED BY THE
AXLE AND TRAILING ARM TO ENSURE ADEQUATE
SUPPORT OF REAR AXLE.
(3) Support the rear axle assembly at both the axle
channel and the trailing arm (Fig. 6). Then remove
lower shock absorber to rear axle mounting bolt (Fig.
6).
(4) Remove hanger bracket to frame rail bolts (Fig.
7).
(5) Lower axle assembly down enough to remove
pivot bolt and hanger bracket (Fig. 7). Right side
trailing arm shown.
PIVOT BUSHING REMOVAL FROM AXLE AS- SEMBLY
Remove bushing with Remover/Installer Spe-
cial Tool C-4212-L (Press) and 3 piece set, Spe- cial Tool 6122 (Receiver Support Bridge, Bushing
Remover/Installer and Bushing Remover). (1) Install receiver (support) bridge into base of
press C-4212-L and bushing Remover/Installer disc
onto screw. (2) Position assembly with receiver bridge support-
ing trailing arm while turning screw to begin bushing
removal. (3) After bushing has begun to move replace bushing
remover/installer (round disc) with bushing remover
(oval shaped disc). Use this assembly to finish pressing
bushing out of trailing arm (Fig. 8).
PIVOT BUSHING INSTALLATION
(1) Align the bushing with the bushing mounting
hole in the trailing arm bracket (Fig. 9). Tap bushing in
slightly to hold position. (2) Assemble bushing installer Tool onto press screw
and support bridge into press base. Position assem-
bly as shown in (Fig. 10) and press bushing into
arm to depth shown in (Fig. 9). (3) Position hanger bracket on pivot bushing, and
install through bolt, loose assemble nut (Fig. 11). Right
side trailing arm shown. (4) Position hanger to frame rail (a suitable drift will
aid in guiding hanger bracket into position). Install
and tighten screws to 75 N Im (55 ft. lbs.) torque (Fig.
12). Install lower shock absorber mounting bolt, but
do not tighten. (5) Position brake hose mounting bracket to trailing
arm, install and tighten retaining screw to 11 N Im (95
in. lbs.) torque (Fig. 13). (6) Attach park brake cable housing to hanger
bracket and cable to connector.
Fig. 8 Tools Installed To Remove Bushing
Fig. 6 Remove Pivot Bushing Hanger Bracket Bolts
Fig. 7 Remove Hanger Bracket
Ä SUSPENSION AND DRIVESHAFTS 2 - 53

PIVOT BUSHING AC AG AJ AP BODY
REMOVE FROM VEHICLE
(1) Raise vehicle (see Hoisting, Group 0). Remove
brake hose mounting bracket screw (Fig. 1). (2) Detach park brake cable at connector and from
hanger bracket (Fig. 1).
WARNING: WHEN REMOVING THE REAR AXLE
PIVOT BUSHING ON VEHICLES EQUIPPED WITH EI-
THER REAR COIL SPRINGS OR AIR SUSPENSION.
THE REAR AXLE MUST BE SUPPORTED BY THE
AXLE AND TRAILING ARM TO ENSURE ADEQUATE
SUPPORT OF REAR AXLE. (3) Support the rear axle assembly at both the axle
channel and the trailing arm with jack stands (Fig.
2). Then remove lower shock absorber to rear axle
mounting bolt (Fig. 2).
(4) Remove hanger bracket to frame rail bolts (Fig.
3). (5) Lower axle assembly down enough to remove
pivot bolt and hanger bracket (Fig. 3). Right side
trailing arm shown.
PIVOT BUSHING REMOVAL FROM AXLE AS- SEMBLY
Remove bushing with Remover/Installer Spe-
cial Tool C-4702-7 Press. And 3 piece set, Special
Tool C-4212 and C-4366-1 (Receiver Support
Bridge, Bushing Remover/Installer and Bushing
Remover). (1) Install receiver (support) cup C-4366-1 into base
of press C-4212 and Bushing Remover Cup C-4702-7
onto screw. (2) Position assembly with receiver bridge support-
ing trailing arm while turning screw to begin bushing
removal. (3) After bushing has begun to move replace bushing
remover/installer (round disc) with bushing remover
(oval shaped disc). Use this assembly to finish pressing
bushing out of trailing arm (Fig. 4).
PIVOT BUSHING INSTALLATION
(1) Align the bushing with the bushing mounting
hole in the trailing arm bracket (Fig. 5). Tap bushing in
slightly to hold it in position on trailing arm. (2) Assemble Bushing Installer Special Tool
C-4702-2 onto press screw and Support Cup Special
Fig. 1 Remove Brake Hose Mounting Bracket Screw and Park Brake Cable
Fig. 2 Remove Pivot Bushing Hanger Bracket Bolts
Fig. 3 Remove Hanger Bracket
Fig. 4 Tools Installed To Remove Bushing
Ä SUSPENSION AND DRIVESHAFTS 2 - 55

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

(3) Position the tubing in the jaws of the Flaring
Tool so that it is flush with the top surface of the
flaring tool bar assembly. (See Fig. 17). (4) Install the correct size adaptor for the brake
tubing being flared, on the feed screw of the yoke as-
sembly. Center the yoke and adapter over the end of
the tubing. Apply lubricant to the adapter area that
contacts brake tubing. Making sure the adapter pilot
is fully inserted in the end of the brake tubing.
Screw in the feed screw of the yoke assembly until
the adaptor has seated squarely on the surface of the
bar assembly (Fig. 17). This process has created the
(metric) ISO tubing flare.STOP LAMP SWITCH ADJUSTMENT (ALL
VEHICLES)
The stop lamp switch incorporates a self adjusting
feature. If adjustment or replacement is required,
proceed as follows: Install the switch in the retaining
bracket and push the switch forward as far as it will
go. The brake pedal will move forward slightly (Fig.
18). Gently pull back on the brake pedal bringing the
striker back toward the switch until the brake pedal
will go back no further. This will cause the switch to
ratchet backward to the correct position. Very little
movement is required, and no further adjustment is
necessary.
Fig. 17 ISO Tubing Flare ProcessFig. 18 Stop Lamp Switch
BASIC DIAGNOSIS GUIDE
Ä BRAKES 5 - 13