Repair Procedure

This bulletin involves installing a revised set of front brake shoes.

1. Clean master cylinder reservoir and filler caps.

2. Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid.

3. Raise and support the vehicle.

4. Remove front wheel and tire assemblies.

5. Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe.

6. Remove the caliper slide pins.

7. Remove caliper from caliper adapter.

CAUTION:
DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES.





8. Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper.





9. Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2).

10. Remove any dirt or foreign material from the wear surface of the rotor.





11. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor's edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement.





12. Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement.

13. Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston.





14. Insert outboard brake shoe into the caliper (Figure 5).





15. Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6).

16. Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges.

17. Install and tighten the caliper slide pins to 25-35 N.m (18-26 ft. lbs.).

NOTE:
START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS.

18. Perform Steps 5 through 17 to the front brakes on the other side of the vehicle.

19. Install the wheel and tire assembly.

20. Remove supports and lower the vehicle.

21. Pump the brake pedal several times to seat the new brake shoes.

CAUTION:
VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE.

22. Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080.

23. Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated.