1993 DODGE TRUCK Service Repair Manual

5
- 14
BRAKES

•
Fig. 8 Combinat
BRAKE LINE AND HOSE REPLACEMENT Factory replacement brake lines and hoses are rec­
ommended to ensure quality, correct length and su­
perior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces are
Valve
Mounting

clean and free from nicks and burrs. Also remember
that right and left brake hoses are not interchange­
able.

Use new copper seal washers at all caliper connec­
tions (Fig. 9). Be sure brake line connections are
properly made (not cross threaded) and tightened to recommended torque.
Brake line routing, connections and tightening
ref­

erence information is outlined in Figures 9 through
12.

Fig. 9 Front Brake
Lines

Fig. 10 Rear Brake Lines And
RWAL
Components

TUBE ASSEMBLY MASTER
CYLINDER TO BRAKE
VALVE REAR (SECONDARY)
BRACKET
AND SHIELD

BRAKE
HOSE AND RWAL
SENSOR
WIRING LET.
TORQUE
LET. POUNDS NEWTON

METRES

x!^ 145 IN.
16
XX 35 FT.
47
170 IN. 19
100 IN.
11

125
IN.
14
BRAKE
VALVE TUBE
TO RIGHT FRONT
BRAKE
HOSE
VIEW IN DIRECTION OF ARROW A
SCREW
<§>
GASKET

8905-54

Fig. 11
Brake
Lines—Two-Wheel
Drive
Models

LET.

TORQUE

LET. POUNDS
NEWTON

METRES

145 IN. 16
125 IN. 14
100 IN. 11
170 IN. 19
SCREW

RIGHT
BRAKE
TUBE

RIGHT

BRAKE
TUBE

BRAKE HOSE BRAKE
VALVE
TUBE

TO
FRONT
BRAKE HOSE
VALVE

VIEW
IN
DIRECTION
OF
ARROW
B
ASSEMBLY
8905-55

Fig. 12 Brake Lines—Four-Wheel Drive Models

•

BRAKES
5-19 BRAKE LINE EMERGENCY REPAIR
Mopar preformed metal brake line is recommended
and preferred for all repairs. However, double-wall
steel line can be used for emergency repair when fac­
tory replacement parts are not readily available.
Special, heavy duty tube bending and flaring
equipment is required to prepare double wall brake

line.
Special bending tools are needed to avoid kink­ ing or twisting metal brake line. In addition, special
flaring tools are needed to provide the inverted-type, double flare required on metal brake lines.
Use tool C-4047 to provide the inverted, double
flare (Fig. 8). Heavy duty tube bending tools are available through the dealer tool program.
Flaring Procedure (1) Cut off damaged tube with tool C-3478-A or an
equivalent tubing cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on section of tube
to be repaired. (4) Insert tube in flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form A over the end of the tube
(Fig. 13).
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter.
(7) Squeeze flaring tool jaws to lock tubing in
place. (8) Insert plug on gauge A in the tube. Then swing compression disc over gauge and center tapered flar­
ing screw in recess of compression disc (9) Tighten tool handle until plug gauge is seated
on jaws of flaring tool. This starts inverted flare (Fig.
13).

(10) Remove plug gauge and complete inverted
flare (Fig. 8). (11) Remove flaring tools and verify that inverted
flare is correct. Flared end must be even, not dis­
torted, too thin, or cracked.
RH222

Fig. 13 Brakeline Flaring Tools

5
- 20
BRAKES

•
POWER BRAKE BOOSTER—BRAKE PEDAL

INDEX

page
Brake Pedal
Installation
21

Brake Pedal Removal
21

General
Information
.......................
20
page
Power Brake Booster
Installation
.............
21

Power Brake Booster Removal
21

GENERAL
INFORMATION
Power brakes
are
standard
on all AD
models.
A

single
or
dual diaphragm, vacuum power brake
booster
is
used. AD
and W150
models
are
equipped with
a
single
diaphragm booster unit
(Fig. 1). D and
W250/350
models
are
equipped with
a
dual diaphragm booster. The booster unit consists
of a
single housing
di­

vided into separate chambers
by one or two
internal
diaphragms.
The
outer edge
of the
diaphragm
is se­

cured
to the
housing. The booster push
rod,
which connects
the
booster
to

the brake pedal
and
master cylinder,
is
attached
to

the center
of the
diaphragm.
A
check valve
is
used
in

the booster outlet connected
to the
engine intake manifold. Power assist
is
produced
by a
combination
of
vac­
uum
and
atmospheric pressure
to
boost brake assist. The power brake booster
is not a
repairable
component.
The
booster must
be
replaced
as an
assembly
if
diagnosis indicates
a
malfunction
has occurred.
AD models with
the
Cummins diesel engine
are

equipped with
a
dual diaphragm power brake
booster.
A
separate vacuum pump assembly supplies the vacuum needed
for
booster operation
(Fig. 2).

The diesel vacuum pump
and the
power steering
pump
are
combined into
a
single assembly. Both
pumps
are
operated
by a
drive gear pressed onto
the

vacuum pump shaft.
The
drive gear
is
operated
by

the camshaft gear. A suspended-type brake pedal
is
used
for all
appli­
cations.
The
pedal
is
attached
to the
pedal support
bracket with
a
pivot shaft.
The
pedal, bolt
and
bush­ ings
are all
serviceable components.
RESERVOIR
PEDAL
SHAFT

RETAINER
SCREW

MASTER
CYLINDER

AND BOOSTER
ASSEMBLY <5>

I
RETAINER
CLIP

TIGHTENING
TORQUE

'A>
200
IN.-LBS.
(23 N-m)

¥>
35
IN.-LBS.
(4 N.m)
LOCKNUT
«
RK721

Fig.
1
Power
Brake
Booster
And
Pedal
Mounting

•

BRAKES
5 - 21

VACUUM

GEAR
ADAPTER
J9105-94

Fig. 2
Diesel
Vacuum
And
Power
Steering
Pump
Assembly
POWER BRAKE BOOSTER REMOVAL

(1) Disconnect vacuum hoses from booster check
valve. (2) Remove nuts attaching master cylinder to
booster and move cylinder away from booster. (3) Inside vehicle, remove clip that secures booster
push rod to brake pedal (Fig. 1). Use screwdriver to ease clip off pedal pivot pin. (4) Remove locknuts from booster mounting studs.
(5) Slide booster away from dash and out of engine
compartment.
POWER BRAKE BOOSTER
INSTALLATION

(1) If new booster is not equipped with check valve
and seal, transfer these parts to new booster. (2) Align and position booster on dash panel.
(3) Install locknuts on booster mounting studs fin­
ger tight. (4) Install booster push rod on brake pedal pin and
secure the rod with a new retaining clip. (5) Tighten booster locknuts to 25 Nth (220 in.
lbs.) torque. (6) Install master cylinder on booster. Then install
and tighten cylinder mounting nuts to 19-23 Nnn
(170-200 in. lbs.) torque. (7) Connect vacuum hose to booster check valve.

BRAKE PEDAL REMOVAL
(1) Disconnect booster push rod from pedal. (2) Remove screw attaching pedal shaft to brake
support. (3) Pull pedal shaft out of support just enough to
remove brake pedal. (4) Slide pedal off shaft and remove it from vehi­

cle.
BRAKE PEDAL
INSTALLATION
(1) Lubricate pedal shaft and bore in brake pedal
with Mopar multi-mileage grease. (2) Position pedal on shaft. Then slide shaft
through pedal and into support. (3) Secure pedal shaft to support with retaining
screw. (4) Attach push rod to pedal.
(5) Verify correct pedal and brake operation before
moving vehicle.