transmission fluid DODGE RAM 2002 Service Repair Manual

DESCRIPTION - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These oils
are specified with a dual SAE viscosity grade which
indicates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
DESCRIPTION - AXLE LUBRICATION
A multi-purpose, hypoid gear lubricant which con-
forms to the following specifications should be used.
Mopar Hypoid Gear Lubricant conforms to these
specifications.
NOTE: Trac-lokTand Powr-lokTequipped axles
require a friction modifier be added to the lubricant.
FRONT AXLE
²The lubricant should have MIL-L-2105C and
API GL 5 quality specifications.
²Lubricant is a thermally stable SAE 80W90.
REAR AXLE
²The lubricant should have MIL-L-2105C and
API GL 5 quality specifications.
²Lubricant is a thermally stable SAE 90W.
DESCRIPTION - TRANSFER CASE - NV241
Recommended lubricant for the NV241 transfer
case is MopartATF+4, type 9602, Automatic Trans-
mission Fluid.
DESCRIPTION - MANUAL TRANSMISSION
MopartManual Transmission Lubricant is recom-
mended or equivalent for use in the manual trans-
missions.
Fig. 4 Engine Oil Viscosity RecommendationÐ
Diesel Engines
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 API Symbol
BR/BELUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid is the recommended fluid for
DaimlerChrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
2500 Series Club Cab
and Quad Cab with 6.5'
Short Box129 L (34 gal.)*****
All 8' Long Box 132 L (35 gal.)*****
All Cab/Chassis Models 132 L (35 gal.)*****
ENGINE OIL WITH FILTER
5.9L 4.7 L (5.0 qts.)
8.0L 6.6 L (7.0 qts.)
5.9L DIESEL 10.4 L (11.0 qts.)
COOLING SYSTEM
5.9L 19 L (20 qts.)****
8.0L 24.5 L (26.0 qts.)****
5.9L DIESEL 22.7 L (24.0 qts.)****
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE 3.8 L (4.0 qts.)
O-haul - 46RE 9-9.5L (19-20 pts.)*
Service Fill - 47RE 3.8 L (4.0 qts.)
O-haul - 47RE 14-16 L (29-33 pts.)*
0 - 6 LUBRICATION & MAINTENANCEBR/BE
FLUID TYPES (Continued)

DESCRIPTION SPECIFICATION
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV4500 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 2.18 L (4.61 pts.)
NV241 HD 3.08 L (6.51 pts.)
FRONT AXLE   .03 L (1 oz)
248-RBI (Model 60) 4.0 L (8.5 pts.)
REAR AXLE   .03 L (1 oz)
248-RBI (Model 60) 2WD 2.9 L (6.1 pts.)
248-RBI (Model 60) 4WD 3.4 L (7.2 pts.)
267-RBI (Model 70)
2WD3.3 L (7.0 pts.)
267-RBI (Model 70)
4WD3.6 L (7.6 pts.)
286-RBI (Model 80)
2WD3.2 L (6.8 pts.)
286-RBI (Model 80)
4WD4.8 L (10.1 pts.)
REAR AXLE - LIMITED SLIP DIFFERENTIAL   .03 L
(1 oz)
248-RBI (Model 60) 2WD 2.8 L (5.9 pts.)
248-RBI (Model 60) 4WD 3.2 L (6.8 pts.)
267-RBI (Model 70)
2WD3.1 L (6.5 pts.)
267-RBI (Model 70)
4WD3.4 L (7.2 pts.)
286-RBI (Model 80)
2WD3.0 L (6.3 pts.)
286-RBI (Model 80)
4WD4.5 L (9.5 pts.)
FRICTION MODIFIER   .03 L (1 oz)
248-RBI (Model 60) 2WD 0.15 L (5 oz)
248-RBI (Model 60) 4WD 0.18 L (6 oz)
267-RBI (Model 70)
2WD0.21 L (7 oz)DESCRIPTION SPECIFICATION
267-RBI (Model 70)
4WD0.24 L (8 oz)
286-RBI (Model 80)
2WD0.21 L (7 oz)
286-RBI (Model 80)
4WD0.30 L (10 oz)
**** Includes 0.9L (1.0 qts.) for coolant reservoir.
*****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
MAINTENANCE SCHEDULES
DESCRIPTION
9Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.9
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²DO NOT JUMP START WHEN MAINTENANCE
FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
BR/BELUBRICATION & MAINTENANCE 0 - 7
FLUID CAPACITIES (Continued)

TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 7)and
(Fig. 8).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
Fig. 7 Jumper Cable Clamp ConnectionsÐGas
Engine
1 - NEGATIVE OR GROUND CABLE CONNECTION
2 - POSITIVE CABLE CONNECTION
3 - BATTERY
Fig. 8 Jumper Cable Clamp ConnectionsÐDiesel
Engine
1 - POSITIVE CABLE CONNECTION
2 - BATTERY
3 - NEGATIVE OR GROUND CABLE CONNECTION
0 - 8 LUBRICATION & MAINTENANCEBR/BE
JUMP STARTING (Continued)

torque supplied to the non-slipping wheel. The differ-
ential resist wheel spin on bumpy roads and provide
more pulling power when one wheel looses traction.
Pulling power is provided continuously until both
wheels loose traction. If both wheels slip due to
unequal traction, operation is normal. In extreme
cases of differences of traction, the wheel with the
least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
3 - 80 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel to complete a
turn. The difference must be compensated for to prevent
the tires from scuffing and skidding through turns. To
accomplish this, the differential allows the axle shafts
to turn at unequal speeds (Fig. 2). In this instance, the
input torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to
rotate at a faster speed.
TRAC-LOKŸ DIFFERENTIAL
The Trac-lokŸ clutches are engaged by two concur-
rent forces. The first being the preload force exerted
through Belleville spring washers within the clutch
packs. The second is the separating forces generatedby the side gears as torque is applied through the
ring gear (Fig. 3).
The Trac-lokŸ design provides the differential
action needed for turning corners and for driving
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. Trac-lokŸ differentials resist wheel
spin on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, Trac-lokŸ
operation is normal. In extreme cases of differences
of traction, the wheel with the least traction may
spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
Fig. 1 STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 108 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)

CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake shoes,
calipers, wheel cylinders, brake drums, rotors, brake
lines, master cylinder, booster, and parking brake
components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear.Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
(4) Check parking brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parking
brake partially applied.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
being loose or for bind condition. Do not road test
until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
ROAD TESTING
(1) If complaint involved low brake pedal, pump
pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
firm under constant foot pressure.
(3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera-
tion such as low pedal, hard pedal, fade, pedal pulsa-
tion, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking
brake only and note grab, drag, noise, etc.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot
pressure is generally the result of a system leak. The
leak point could be at a brake line, fitting, hose, or
caliper/wheel cylinder. If leakage is severe, fluid will
be evident at or around the leaking component.
Internal leakage (seal by-pass) in the master cylin-
der caused by worn or damaged piston cups, may
also be the problem cause.
An internal leak in the ABS or RWAL system may
also be the problem with no physical evidence.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev-
eral times. If the pedal comes back up, worn linings,
rotors, drums, or rear brakes out of adjustment are
the most likely causes. The proper course of action is
to inspect and replace all worn component and make
the proper adjustments.
BR/BEBRAKES - BASE 5 - 5
HYDRAULIC/MECHANICAL (Continued)

(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURE - 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. 19).
The correct fluid level is to the FULL indicator on
the side of the reservoir. If necessary, add fluid to the
proper level.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoir cap and empty fluid into
drain container.
(2) Clamp cylinder body in vise with brass protec-
tive jaws.
(3) Remove pins that retain reservoir to master
cylinder. Use hammer and pin punch to remove pins
(Fig. 20).
(4) Loosen reservoir from grommets with pry tool
(Fig. 21).
(5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 22).
(6) Remove old grommets from cylinder body (Fig.
23).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body (Fig. 24).
Use finger pressure to install and seat grommets.
(2) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
Fig. 19 Master Cylinder Fluid Level - Typical
1 - INDICATOR
2 - RESERVOIR
BR/BEBRAKES - BASE 5 - 15
DISC BRAKE CALIPERS (Continued)

(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: Use only MOPAR power steering fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
(12) Bleed the hydraulic booster.
ROTORS
DIAGNOSIS AND TESTING
DISC BRAKE ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining with a disc
brake lathe if surface scoring and wear are light.
Replace the rotor for the following conditions:
²Severely Scored
²Tapered
²Hard Spots
²Cracked
²Below Minimum Thickness
Fig. 28 Master Cylinder And Booster
1 - MASTER CYLINDER
2 - RETURN LINE
3 - LINE FROM PUMP
4 - HYDRAULIC BOOSTER
5 - LINE TO GEAR
Fig. 29 Booster Push Rod
1 - BOOSTER PUSH ROD
2 - WASHER
3 - CLIP
4 - PEDAL
Fig. 30 Booster Mounting
1 - STEERING COLUMN
2 - MOUNTING NUTS
3 - BOOSTER PEDAL ROD
4 - MOUNTING NUTS
5 - 20 BRAKES - BASEBR/BE
POWER BRAKE BOOSTER (Continued)

(7) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION) (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/DISC BRAKE CALIPERS -
INSTALLATION).
(8) Install wheel and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(9) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(10) Top off master cylinder fluid level.
INSTALLATION - FRONT
(1) Bottom pistons in caliper bore with C-clamp.
Place an old brake shoe between a C-clamp and cal-
iper piston.
(2) Clean caliper mounting adapter and anti-rattle
springs.
(3) Lubricate anti-rattle springs with Mopar brake
grease.
(4) Install anti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
(5) Install inboard brake shoe in adapter.
(6) Install outboard brake shoe in adapter.
(7) Tilt the bottom of the caliper over rotor and
under adapter. Then push the top of the caliper down
onto the adapter.
(8) Install caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(9) Install wheel and tire assemblies and lower
vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(10) Apply brakes several times to seat caliper pis-
tons and brake shoes and obtain firm pedal.
(11) Top off master cylinder fluid level.
MASTER CYLINDER
DESCRIPTION
A two-piece master cylinder is used on all models.
The cylinder body containing the primary and sec-
ondary pistons is made of aluminum. The removable
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the
hydraulic brake circuits. The reservoir is the only
serviceable component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
cuit separation in the event of a front or rear brake
malfunction. The reservoir compartments will retain
enough fluid to operate the functioning hydraulic cir-
cuit.Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
the cylinder fluid ports can be damaged if care is not
exercised. Start all brake line fittings by hand to
avoid cross threading.
The cylinder reservoir can be replaced when neces-
sary. However, the aluminum body section of the
master cylinder is not a repairable component.
NOTE: If diagnosis indicates that an internal mal-
function has occurred, the aluminum body section
must be replaced as an assembly.
OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action. It should
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately turn off igni-
tion to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 47).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
5 - 26 BRAKES - BASEBR/BE
BRAKE PADS/SHOES (Continued)