Document jyG85oo0xrvdJ334q42XmykoO

FILE NAME: Chrysler (CHRY) DATE: 1974 DOC#: CHRY128 DOCUMENT DESCRIPTION: Dodge Truck Manual SAFETY NOTICE The safe and reliable operation of motor vehicles depends on proper service and repair procedures. This service manual describes suggested and recom mended methods for performing these service and repair procedures. Special tools as required in performing certain service operations are so iden tified in the service manual and are recommended for use. Use of tools or procedures other than those recommended in this service manual could be detrimental to the vehicle's safe operation as well as the safety of the person or persons servicing the vehicle. CHRYSLER 7 3 0 9 5-S BRAKES-- HYDRAULIC----------------------- CHRYSLER 967312 Condition__________ _______________________Possible Causa Correction (c) Sticking brakes.' (d) Master cylinder low on brake fluid. (c) Lubricate brake pivots and support platforms. (d) Fill master cylinder and inspect for leaks. BRAKES APPLY SLOWLY (a) Improper brake adjustment or lack of lubrication. (a) Adjust brakes and lubricate linkage. SPONGY PEDAL (a) Air in hydraulic system. (b) Swollen rubber parts due to contaminated brake fluid. (c) Improper brake shoe adjustment (d) Brake fluid with low boiling point (e) Brake drums ground excessively. (a) Fill and bleed hydraulic system, (b) Clean hydraulic system and recondition wheel cylinders and master cylinder. (c) Adjust brakes. (d) Flush hydraulic system and refill with proper brake fluid. (e) Replace brake drums. ERRATIC BRAKES (a) Linings soaked with grease or brake fluid. (b) Primary and secondary shoes mounted in wrong position. (a) Correct the leak and replace brake lining. (b) Match the primary and secondary shoes and moitnt In proper position. CHATTERING BRAKES (a) Improper adjustment of brake shoes. , (b) Loose front wheel bearings. (c) Hard spots in brake drum. (d) Out-of-round brake drums. (e) Grease or brake fluid on lining. (a) Adjust brakes. (b) Clean, pack and adjust wheel bearings. (c) Grind or replace brake drums. (d) Grind or replace brake drums. (e) Correct leak and replace brake lining. SQUEALING BRAKES (a) Incorrect lining. (a) Install correct lining. (b) Distorted brake drum. (b) Grind or replace brake drum. (c) Bent brake support plate. (c) Replace brake support plate. (d) Bent brake shoes. (d) Replace brake shoes. r (e) Foreign material embedded in (e) Replace brake shoes. brake lining. (f) Dust or dirt in brake drum. (f) Use compressed air and blow out drums and support plate and shoes. (g) Shoes dragging on support (g) Sand support plate platforms Iitt plate. and lubricate. i(lI (h) Loose support plate. (h) Tighten support plate attaching nuts. (i) Loose anchor bolts. . (j) Loose lining on brake shoes or (i) Tighten anchor bolts. (j) Replace brake shoes and . . - improperly ground lining. cam-grind lining. BRAKES FADING v.-.o ................... ` . DRAGGING BRAKES (a) Improper brake adjustment (b) Improper brake lining. (c) Improper type of brake fluid. (d) Brake drums ground excessively. (a) Improper brake adjustment (b) Distorted cylinder cups. (c) Brake shoe seized on anchor bolt (d) Broken brake shoe return spring. (e) Loose anchor bolt (f) Distorted brake shoe. (g) Loose wheel bearings. (h) Obstruction in brake line. (a) Adjust brakes correctly. (b) Replace brake lining. (c) Drain, flush and refill hydraulic system. (d) Replace brake drums. (a) Correct adjust brakes. (b) Recondition or replace cylinder. (c) Clean and lubricate anchor bolt (d) Replace brake shoe return spring. (e) Adjust and tighten anchor bolt (f) Replace defective brake shoes. (g) Lubricate and adjust wheel bearings. (h) Clean or replace brake line. CHRYSLER 007331 SERVICE-BRAKES 5-21 anchoi LEVER RETURN SPRING PRIMARY SHOE AND UNING t t o p r e p S S " UX `i " LEVER . ADJUSTING STAR w heel PRONT O ^ h ic r ig h t REAR) 9 -R e a r Brak Assemblies (D200) Sl" UM "* mM" TM i SHOE INSTALUTION R ET A IN E R , NAIL T a n o spr in g LEVER r e t u r n Front Brake Shoos . ' *- > n " p i ^ nf 2 n. 7 ' i " V " 0"'1" brale 'h o . d r u m .r e f a c in g it Z t T : ,; ' " 4S7 """"ii screw end insUll ) Measure the drum runout with an accurate m u m w b S C 07 C s h r ? , % a wiV * 1 r "t J Sh0Uld not exceed -06 inch o u t8of a r * - - - * s i s a s s e s s 3 S A- Hthf drUm ruBout 15 to ez s s of .006 inch side) and indicate their location on the vehicle Lu- e . (total indicator run-out) the drum should bo re fa c S ' M^l^Piirnos3^ <S t a C t " SUpport ^ M0PA* i cleanup the drum. Do not rofaco mora than 060 L * J S S S t T " p,rt Nrabtt * * - ovarthaafandarddrumdlamatar. ,neh b r i l l ?hVerIap " Ch0r ends of P ^ a i y and secondary b raie shoes and install adjusting spring and lever. *** i r v *a - apt# ^ / (? * ^ V/n or Installing ShS Reten, Springs RETAINERS. SPRINGS ^ J i ANO NAILS ' I _ .s . 0 . 1 1--Removing o r Installing Shoe Retainers, i*i t f & W . ^ t f o a U I ^ J R R o r ) ... V- 5-24 BRAKES--SERVICE---------------- -------- GENERAL INFORMATION The Bendix BX Duo-Servo is a basic Duo-Servo sin gle anchor brake of an advanced and improved de sign. Front and rear brake assemblies are basically the same except that the rears include a parking brake lever and cam plate. (Fig. 1). All are self adjust ing. A two-piston wheel cylinder is mounted in an in dention on the support plate. The wheel cylinder must be removed from the support plate for servic ing. Each brake shoe is held against the support plate by a coil spring-hold down pin combination (Fig. 2). Each support plate has six guide pads, three for each shoe (Fig. 3). The shoe webs ride against these pads. Brake shoes are marked pri. (primary) and sec. (secondary) and also "This Side Out" for easy identifi cation and application. Typical front and rear assembly are shown in (Figs. 4 and S). SERVICE PROCEDURES BRAKE DRUM REMOVAL (4) Remove shoes with lower shoe-to-shoe spring and star wheel as an assembly (Fig. 10). Front (1) Raise vehicle on hoist or jacks and install jack stands for safety. Rear r (1) Unhook adjusting lever return spring from the (2) Remove wheel and tire assembly. lever (Fig. 1). Remove lever and return spring from (3) Remove dust cover, cotter key, nut, lock nut, lever pivot pin. Unhook adjuster lever from adjuster washer and outer bearing. Carefully remove drum. cable assembly. CAUTION: If there Is interference between brake (2) Using brake spring pliers (Tool C-312) (Fig. 11) shoes and drum, remove hole cover and using a unhook upper shoe-to-shoe spring. Unhook and re screwdriver and light piece of metal, ralease brake move shoe hold down springs (Fig. 12). shoes (Fig. 6). (3) Disconnect parking brake cable from parking Rear (1) Raise vehicle on hoist or jacks and install jack stands for safety. brake lever.. (4) Remove shoes with lower shoe-to-shoe spring and starwheel as an assembly (Fig. 13). (2) Remove wheel and tire assembly. (3) Remove axle shaft nuts, washers and cones. DRUM REFACING Rap axle shaft sharply in center to release cones if Measure the drum runout with an accurate gauge. they do not readily release. Remove axle shaft Drum runout should not exceed .006 inch out of (4) Using Tool DD-1245 remove outer hub n u t round. If the drum runout is in excess of .006 inch, Straighten lock washer, remove i t inner nut and (total indicator run-out) the drum should be refaced. bearing. Carefully remove drum. . Remove only as much material as is necessary to CAUTION: If there is : interference between brake clean up the drum. Do not reface more than .060 inch shoes and drum, remove h.o!e...cover and using a over the standard drum diameter. - screwdriver and light'piece' of..metal, release brake shoes (Fig. 6).*. ' ; CLEANING AND INSPECTION BRAKE SHOES REMOVAL ^ " ^ ''' ? ; v> ' Wipe o f brush clean (dry) the metal portions of the brake shoes. Examine the lining contact pattern to Front . : ,-.(1) Unhook adjusting lever return spring from the lever (Fig. 1). Remove lever and return spring from .lever pivot pin. Unhook adjuster lever from adjuster .cable assembly. " -- determine if the shoes are b en t The lining should show contact across the entire width, extending from heel to toe. Shoes showing contact only on one side should be replaced. Shoes having sufficient lining but lack of contact at toe and heel should be measured (2) ' Remove cable retaining clip (Fig. 7) and refor proper grind. .... * -move cable. . . . . ...................... --* Clean the support, using a suitable solvent then in (3) Using brake spring pliers (Tool C-312) (Fig. 8) spect for burrs. Remove if necessary. Clean the `unhook upper shoe-to-shoe' spring. Unhook and re threads of the adjusting screws, then inspect for & move shoe hold down springs (Fig- 9).. V*v f i ^ t s d ^ v t i w w o . * ** * 7 " K -. pulled or stripped threads.. CHRYSLER 007334 V * AN CHOR BOLT H.' I . II f l> '.' I '* CA B LE-------- _ I) RETAINING CUP i ` . * PARKING BRAKE LEVER * PARTS USED ON REAR BRAKES ONLY ** PART USED ON FRONT BRAKES ONLY AU TO M ATIC ADJUSTER LEVER Fig. I--Front a n d R oar Brak A nom bJJos ADJUSTER LEVER RETURN SPRING PY1233 SERVICE-- BRAKES 5-25