Service Adjustments</title<link href="/diplomat.css" rel="stylesheet" type="text/css"> </head> <body><div id="content"> <table border="0" cellpadding="6" bgcolor="#99CCFF" align="center"> <tr class="menus"> <th><a href="/index.html">Home</a></th> <th><a href="/info/index.html">Diplomat Info</a></th> <th><a href="/registry/index.html">Registry</a></th> <th><a href="/upgrade/index.html"> Upgrades</a></th> <th><a href="/photo/index.html">Photos</a></th> <th><a href="/links.html">Links</a></th> <th><a href="/farley/index.html">Farley</a></th><th><a href="/tools/index.html">Site Tools</a></th> <th><a href="/svcman/index.html">Manual</a></th> <th><a href="https://www.dippy.org/forum2/">Forum</a></th> </tr> </table> <p> </p> <p align="center"><img src="/graphic/site/diplomat-cars.jpg" alt="Dodge Diplomat cars banner" width="792" height="77"></p> <script async src="//pagead2.googlesyndication.com/pagead/js/adsbygoogle.js"></script>  <ins class="adsbygoogle" style="display:block" data-ad-client="ca-pub-7865546952023728" data-ad-format="auto"></ins> <script> (adsbygoogle = window.adsbygoogle || []).push({}); </script> <table border="0" cellpadding="2" width="800"> <tr> <td><style type="text/css"> @import url(http://www.google.com/cse/api/branding.css); </style> <div class="cse-branding-right" style="background-color:#000000;color:#FFFFFF"> <div class="cse-branding-form"> <form action="https://www.dippy.org/search-results.php" id="cse-search-box"> <div> <input type="hidden" name="cx" value="partner-pub-7865546952023728:5994239894" /> <input type="hidden" name="cof" value="FORID:10" /> <input type="hidden" name="ie" value="ISO-8859-1" /> <input type="text" name="q" size="31" /> <input type="submit" name="sa" value="Search" /> </div> </form> </div> <div class="cse-branding-logo"> <img src="http://www.google.com/images/poweredby_transparent/poweredby_000000.gif" alt="Google" /> </div> <div class="cse-branding-text"> Custom Search </div> </div> </td> <td width="250"><table border="1" cellspacing="1" width="100%" bgcolor="#52ABD6"> <tr> <td width="25%" bgcolor="#000000"> <p align="center"><a href="../index.html"><b>HOME</b></a><br> <nobr><a href="sm05b.html">Next</a></nobr><br><a href="../tools/whatsnew.html">New</a><br> <a href="../tools/sitemap.html">Map</a></font></td> <td width="75" bgcolor="#000000"><nobr><a href="sm05.html">Up</a></nobr><br><nobr>Service Adjustments</nobr><br><nobr><a href="sm05b.html">Drum Brakes</a></nobr><br><nobr><a href="sm05c.html">Master Cylinder</a></nobr><br><nobr><a href="sm05d.html">Hydraulic System Control Valves</a></nobr><br><nobr><a href="sm05e.html">Wheel Cylinders</a></nobr><br><nobr><a href="sm05f.html">Parking Brakes</a></nobr><br><nobr><a href="sm05g.html">Power Brakes (Bendix)</a></nobr><br><nobr><a href="sm05h.html">Disc Brakes</a></nobr><br><nobr><a href="sm05i.html">Braking Disc (Rotor)</a></nobr> </font></td> </tr> </table></td> <td width="375"><table border="1" cellspacing="1" width="100%" bgcolor="#52ABD6"> <tr> <td bgcolor="#000000"> <table border="0" cellpadding="3" cellspacing="1" width="100%"> <tr> <td width="10%"><img src="../graphic/site/smallhood.gif" alt="Dodge Diplomat cars" width="30" height="45"></font></td> <td width="90%"><font face="Arial"><font color="#999999" size="1">www.dippy.org</font><br><strong><font color="#FFFFFF" size="3">Service Adjustments</font></strong></font></td> </tr> </table> </td> </tr> </table></td> </table> </td></tr></table> </td><td valign="top" width="24"></td><td valign="top"> <p><a name="TOP"><font color="#000000" size="2">.</font></a></p> <p> <b> INDEX</b> </font> <p><b><a href="#ADJUSTING">Adjusting Service Brakes</a><br> <a href="#BLEEDING"> Bleeding Brake System</a><br> <a href="#BRAKE"> Brake Hose and Tubing</a><br> <a href="#MASTER"> Master Cylinder Fluid Level</a><br> <a href="#DIAGNOSIS">Service Diagnosis</a><br> <a href="sm05.html#SPECIAL"> Special Tools</a><br> <a href="#STOP"> Stop Lamp Switch Adjustment</a><br> <a href="#TEST"> Test for Fluid Contamination</a><br> <a href="#TESTING"> Testing Application Adjuster Operation</a><br> <a href="#WHEEL"> Wheel Stud Nut Tightening</a></b></font> <p><b><a name="ADJUSTING">ADJUSTING</a> SERVICE BRAKES</b> (<a href="#TOP">back to CONTENTS</a>) </font> <p><b>Normally self adjusting drum brakes will not require manual adjustment but in the event of a brake reline it is advisable to make the initial adjustment manually to speed up the adjusting time.</b><br> (1) Jack up vehicle so all wheels are free to turn.<br> (2) Remove rear adjusting hole plugs from brake supports of vehicle.<br> (3) <b> Be sure parking brake lever is fully released, then back off parking brake cable adjustment so there is slack in cable.</b><br> (4) Insert adjusting tool C-3784, into star wheel of adjusting screw. Move handle of tool upward until a slight drag is felt when road wheel is rotated.<br> (5) Insert a thin screwdriver or piece of welding rod into brake adjusting hole and push adjusting lever out of engagement with star wheel (models with Iso-Clamp rear suspension, bend welding rod to match adjusting tool angles plus a 3/4 reverse bend at contact end), (Fig. <a href="image/05a01.jpg">1</a>). <b> Care should be taken so as not to bend adjusting lever or distort lever spring. </b> While holding adjusting lever out of engagement, back off star wheel to insure a free wheel with no brake shoe drag.<br> (6) Repeat above adjustment at each wheel. The adjustment must be equal to all wheels. Install adjusting hole plugs in brake supports.<br> (7) Adjust parking brake after wheel brake adjustment. </font> <p><b> It is important to follow the above sequence to avoid the possibility of the parking brake system causing brake drag, if the parking brakes are adjusted before the service brakes.</b> </font> <p><a href="image/05a01.jpg"><img border="0" src="image/05a01_small.jpg" alt="FIG.1 - Adjusting Service Brakes" width="93" height="100"></a> <p><b><a name="TESTING"> TESTING</a> APPLICATION ADJUSTER OPERATION</b> (<a href="#TOP">back to CONTENTS</a>)</font> <p>Place the vehicle on a hoist, with a helper in the driver�s seat to apply the brakes. Remove the access plug from the rear adjustment slot in each brake support plate to provide access to the adjuster star wheel. Then, to eliminate the possibility of maximum adjustment, whereby the adjuster does not operate because the closest possible adjustment has been reached, back the star wheel off approximately 30 notches. It will be necessary to hold the adjuster lever away from the star wheel to permit this adjustment. </font> <p>Spin the wheel and brake drum in the reverse direction and with greater than normal force apply the brakes suddenly. This sudden application of force will cause the secondary brake shoe to leave the anchor. The wrap up effect will move the secondary shoe, and the cable will pull the adjuster lever up. Upon application of the brake pedal, the lever should move upward, turning the star wheel. Thus, a definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly. If one or more adjusters do not function properly, the respective drum must be removed for adjuster servicing. </font> <p><b><a name="MASTER">MASTER</a> CYLINDER FLUID LEVEL</b></font> <p>Check the fluid level in the master cylinder twice a year. The master cylinder black nylon reservoir is marked with the words �fill to bottom of rings� indicating proper fluid level. Remove the caps to check the level. <b> Wipe caps and reservoir clean to prevent dirt and foreign matter from dropping into the reservoir.</b> </font> <p>If necessary, add fluid to bring level to bottom of rings in reservoir. <b> With disc brakes, fluid level can be expected to fall as the brake pads wear.</b> Use only brake fluid conforming to DOT 3. MOPAR Brake Fluid is a fluid of this quality and is recommended to provide best brake performance. <b> Use of a brake fluid that may have a lower Initial boiling point, such as fluid Identified as 70R1 or unidentified as to specification may result in sudden brake failure during hard prolonged braking.</b> Use only brake fluid that has been stored in a tightly closed container, to avoid contamination with foreign matter or moisture. </font> <p><b>CAUTION: Do not allow petroleum base fluid to contaminate the brake fluid. Seal damage will result.</b> </font> <p><b><a name="BLEEDING">BLEEDING</a> BRAKE SYSTEM</b></font> <p>Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder� reservoir when the cover is removed. </font> <p>Using the one man bleeder tank C-3496-B (with adapter C-4578) provides a convenient means for pressurizing the hydraulic system for bleeding. (Complete bleeding of the dual master cylinder is important! See <a href="sm05c.html#BLEEDING"> Bleeding the Master Cylinder</a> in this Group.) </font> <p>Starting with the right rear wheel clean all dirt from the bleeder valve. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. (This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. Follow the manufacturers instructions in the use of the bleeder tools). </font> <p>Continue this bleeding operation with the left rear wheel, then the right front and finishing with the left front wheel. </font> <p>If necessary, repeat this bleeding operation if there is any indication (a spongy brake pedal or warning light) of air remaining in the hydraulic system. </font> <p><b>Brake System Bleeding Procedures<br> </b> All vehicles are equipped with a pressure holdoff valve. The valve is located (in the combination valve) on the left side of the engine compartment. The use of the hold-off valve is to better match front disc brakes with the rear drum brakes, resulting in improved braking and steering control on icy surfaces. </font> <p>Due to operating characteristics of the valve, which causes complete shut-off of the flow of brake fluid between approximately 3 and 135 psi, front brake bleeding procedures should be done as follows:<br> (1) <b> Gravity Bleed:</b> This method of bleeding is not affected by the hold-off valve, as fluid pressures are always below 3 psi. Remove master cylinder reservoir cover and gasket, then fill reservoirs with approved brake fluid. Open disc brake bleeder screws, and allow fluid and air to drain until stream of fluid is free of air.<br> (2) <b> Pedal Bleed:</b> This method of bleeding is not affected by the hold-off valve, as fluid pressures are in excess of 135 psi. Follow normal procedure of pumping pedal and opening bleeder screws. <b> Do not pump master cylinder dry!</b><br> (3) <b> Pressure Bleed:</b> This method of bleeding is influenced by the hold-off valve. Bleed pressure, normally about 35 psi, is high enough to cause the hold-off valve to close, stopping the flow of fluid to the front brakes. However, the valve (Fig. <a href="image/05a02.jpg">2</a>) must be held open manually by using <b> Tool C-4121</b>, to pull the valve stem out. </font> <p><b>CAUTION: Under no condition should a rigid clamp, wedge or block be used to depress the valve stem, as this can cause an internal failure in the valve, resulting in complete loss of front brakes.</b> </font> <p> It should be noted that the pressure release valve stem is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. </font> <p>If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. (See - <a href="sm05c.html#BLEEDING">Bleeding Master Cylinder</a>). After brake tubes are connected, have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened.</font> <p><a href="image/05a02.jpg"><img border="0" src="image/05a02_small.jpg" alt="FIG. 2 - Holding Valve, Stem Extended" width="100" height="69"></a> <p><b><a name="TEST">TEST</a> FOR FLUID CONTAMINATION</b></font> <p>Swollen rubber parts indicate the presence of petroleum in the brake fluid. To confirm that contamination exists, make the following test. </font> <p>Place a small amount of the drained brake fluid into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. </font> <p><b>If there is any question of mineral oil content, drain system, flush thoroughly and replace all rubber parts.</b> </font> <p><b><a name="WHEEL">WHEEL</a> STUD NUT TIGHTENING</b></font> <p><b>The tightening sequence and torquing of the wheel stud nuts is of great importance to insure efficient brake operation. The use of an impact or long handled wrench may distort the drum.</b> </font> <p>Use a criss-cross tightening sequence (Fig. <a href="image/05a03.jpg">3</a>). Tighten all the stud nuts to one-half the specified torque first, and then repeat the sequence tightening to the specified 85 ft. lbs. (115 N�m) </font> <p><a href="image/05a03.jpg"><img border="0" src="image/05a03_small.jpg" alt="FIG. 3 - Wheel Stud Nut Tightening Sequence" width="100" height="80"></a> <p><b><a name="BRAKE"> BRAKE</a> HOSE AND TUBING</b></font> <p><b>Inspection of Brake Hose and Tubing<br> </b> Flexible rubber hose is used at both front brakes and at a rear axle junction block. </font> <p>Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for severe surface cracking, scuffing, or worn spots. Should the fabric casing of the rubber hose be exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately! Eventual deterioration of the hose can take place with possible burst failure. </font> <p>Faulty installation can cause twisting, and wheel, tire or chassis interference. </font> <p><b>Installation of Brake Hose<br> </b> Always use factory recommended hose to insure quality, correct length and superior fatigue life. Care should be taken to make sure that the tube and hose mating surfaces are clean and free from nicks and burrs. <b> Right and left brake hoses are not interchangeable.</b> </font> <p>Use new copper seal washers and all connections should be tight and properly made. </font> <p>The flexible hydraulic brake hose should always be installed on the vehicle by first tightening the block end of the hose onto caliper, or rear axle housing tee. The intermediate bracket should then be bolted to the suspension �k� member. The hose should then be attached to the hose bracket in a manner to give minimum twist with the wheel in a straight ahead position. (15 degrees twist is the maximum recommended). Excessive twist can result in hose interference problems with possible hydraulic system failure. Finally, the tube is attached to the hose. </font> <p><b>Repair and Installation of Brake Tubing<br> </b> Double wall steel tubing should always be used for replacement. Care should be taken when replacing brake tubing to use the proper bending and flaring tools and to avoid kinking or routing the tubes against sharp edges, moving components or in hot areas. All tubes should be properly attached with recommended retaining clips. </font> <p>Steel tubing is used to conduct hydraulic pressure to the front and rear brakes. Steel tubing is used from the junction block to both rear wheel cylinders. All fittings, tubing and hoses should be inspected for rusted, damaged or defective flaring seats. The steel tubing is equipped with a double flare inverted seat to insure more positive seating in the fitting. To repair or reflare tubing proceed as follows:<br> (1) Using Tool C-3478-A, or equivalent, cut off damaged seat or damaged tubing (Fig. <a href="image/05a04.jpg">4</a>).<br> (2) Ream out any burred or rough edges showing on inside edges of tubing. This will make the ends of tubing square and insure better seating of flared end tubing. <b> Place tube nut on tubing prior to flaring tubing.</b><br> (3) To flare tubing open handles of flaring Tool C-4047 and rotate jaws of tool until the mating jaws of tubing size are centered in area between vertical posts.<br> (4) Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place.<br> (5) Place gauge �Form A� on edge over end of tubing and push tubing through jaws until end of tubing contacts the recessed notch of gauge matching the size of tubing (Fig. <a href="image/05a04.jpg">4</a>).<br> (6) Squeeze handles of flaring tool and lock tubing in place.<br> (7) Place 3/16 inch plug of gauge �A� down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc.<br> (8) Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing.<br> (9) Remove gauge and continue to screw down until tool is firmly seated in tubing.<br> (10) Remove tubing from flaring tool and inspect seat. </font> <p><a href="image/05a04.jpg"><img border="0" src="image/05a04_small.jpg" alt="FIG. 4 - Cutting and Flaring Steel Tubing" width="91" height="100"></a> <p><b><a name="STOP">STOP</a> LAMP SWITCH ADJUSTMENT</b></font> <p>The stop lamp (or stop lamp/speed control) switch and mounting bracket assembly is attached to the brake pedal bracket. The switch is actuated by the brake pedal blade on all models. </font> <p>Refer to figure <a href="image/05a05.jpg"> 5</a> for proper switch adjustment as follows:<br> (1) Loosen switch assembly to pedal bracket attaching screw and slide assembly away from pedal blade or striker plate.<br> (2) Push brake pedal down and allow to return to free position, do not pull brake pedal back at any time.<br> (3) Place proper spacer gauge on pedal blade. A clearance of .130 to .150 inch required for the heavy duty stop lamp switch, and .060 to .080 inch for the stop lamp/speed control switch.<br> (4) Slide switch assembly toward pedal blade until switch plunger is fully depressed against spacer gauge (on heavy duty or stop light/speed control switches, depress plunger until switch body contacts spacer gauge).<br> (5) Re-tighten switch bracket screw to 75 in. lbs. (8 N�m).<br> (6) Remove spacer. Be sure that stop lamp switch does not prevent full pedal return.</font> <p><a href="image/05a05.jpg"><img border="0" src="image/05a05_small.jpg" alt="FIG. 5 - Stop Lamp Switch Adjustment" width="75" height="100"></a><p><b><a name="DIAGNOSIS">SERVICE DIAGNOSIS</a></b> (<a href="#TOP">back to CONTENTS</a>)</font><p><a href="image/05a06.jpg"><img border="0" src="image/05a06_small.jpg" alt="FIG. 6 - Brake Line Routing, All Models" width="100" height="73"></a> <p><b><a name="GUIDE">Basic</a> Diagnosis Guide</b></font></p> <table border="1" cellpadding="0" cellspacing="0" width="600"> <tr> <td width="40%"><b>Symptom</b></font></td> <td width="10%" align="center"><b><a href="#C1">Chart 1</a><br> Misc. Cond.</b></font></td> <td width="10%" align="center"><b><a href="#C2">Chart 2</a><br> Actuation</b></font> </td> <td width="10%" align="center"><b><a href="#C3">Chart 3</a><br> Power</b></font> </td> <td width="10%" align="center"><b><a href="#C4">Chart 4</a><br> Noise</b></font> </td> <td width="10%" align="center"><b><a href="#C6">Chart 5</a><br> Wheel<br> Brakes</b></font> </td> <td width="10%" align="center"><b><a href="#C6">Chart 6</a><br> Pull</b></font> </td> </tr> <tr> <td width="40%">Brake Warning Light "On"</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Excessive Pedal Travel - Spongy Pedal</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Pedal Goes to Floor</font></td> <td width="10%" align="center"><b>6</font></b></td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Stop Light "On" All The Time</font></td> <td width="10%" align="center"><b>3</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Brakes Drag - Front or All</font></td> <td width="10%" align="center"><b>5</font></b></td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Rear Brakes Drag</font></td> <td width="10%" align="center"><b>2</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Grabby Brakes</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Excessive Pedal Effort</font></td> <td width="10%" align="center"><b>1</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Rough Engine Idle</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>O</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Brake Chatter (Rough)</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Surge During Braking</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Noise During Braking</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Pedal Pulses During Braking</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Rattle or Clunking Noise</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Premature Rear Wheel Lockup</font></td> <td width="10%" align="center"><b>4</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> <td width="10%" align="center"> </td> </tr> <tr> <td width="40%">Pull to Right or Left</font></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"><b>NO</font></b></td> <td width="10%" align="center"> </td> <td width="10%" align="center"><b>X</font></b></td> <td width="10%" align="center"><b>X</font></b></td> </tr> <tr> <td width="100%" colspan="7"> <p align="center"><b>X</b> - Most Likely Cause <b>O</b> - Possible Cause <b>NO</b> - Not Possible Cause</font></td> </tr> </table> <p><b><a name="C1">Brake</a> Chart 1 Diagnosis - Miscellaneous Conditions</font></b> (<a href="#GUIDE">back to Diagnosis Guide</a>)</font><p><b>Miscellaneous Conditions</b></font> <font color="#FFFF00"><i> Excessive pedal effort</font></i></font><i><font color="#FFFF00"><br> </font><font color="#00FF00"> All the time<br> </font></i> Blocked or pinched rear line or hose<br> Poor vacuum supply to booster<br> Dragging brakes - see 2 and 5<br> <font color="#00FF00"><i> </i> <i> Only after several stops<br> </i></font> Improper lining<br> Excessive use, riding brakes, mountain descent in high gear<br> <font color="#FFFF00"><i> Rear brakes drag<br> </i></font> Parking brake dragging, check adjustment<br> Weak return springs<br> Frozen pistons<br> Contaminated fluid or lining<br> <font color="#FFFF00"><i> Stop lights on all the time<br> </i></font><b> </b> Inspect for correct pedal linkage<br> Inspect for binding stop light switch adjustment<br> <font color="#FFFF00"><i> Premature rear wheel lockup<br> </i></font> Contaminated rear lining, inspect<br> Inoperative proportion valve, test<br> <font color="#FFFF00"><i> Front or all brakes drag<br> </i></font> Misadjusted stop light switch - prevents full pedal return<br> Contaminated fluid - seals swollen<br> Pedal or linkage binding or incorrectly assembled<br> Booster defect (very rare)<br> <font color="#FFFF00"><i> Pedal goes to floor, warning lamp does not light<br> </i></font> Booster runout (Maximum Assist Point) is often mistaken for the pedal hitting the floor,<br> especially when the car is not moving. The change in pedal effort at runout is interpreted as<br> bottoming the pedal. Check by opening and closing a fitting and allowing the pedal to move.</font><p><b><a name="C2">Brake</a> Chart 2 - Actuation Diagnosis</b></font><p><b>Check Warning Light (Ignition On)</b><br> <i><font color="#FFFF00"> </font></i> <i><font color="#FFFF00">Light "on" indicating malfunction<br> </font></i> Remove master cylinder reservoir caps - check fluid level<br> <i><font color="#00FF00"> Fluid level OK<br> </font></i> Examine diaphragm and fluid for signs of contamination, diaphragm swollen, etc<br> <i><font color="#00FFFF"> Contaminated fluid<br> </font></i> Replace fluid and all rubber parts per service manual<br> <font color="#00FFFF"> <i> </i> <i>Clean fluid<br> </i></font><i> </i>See "Basic Hydraulic Test", below in this chart<br> <font color="#00FF00"><i> </i> <i> Fluid level low (below reservoir seam)<br> </i></font> Check entire system for leaks<br> Repair or replace as required<br> <i><font color="#FFFF00"> </font></i> <i><font color="#FFFF00">Light "off"<br> </font></i> Check warning light circuit<br> Apply parking brake - ignition in Run position<br> <i><font color="#00FF00"> Warning light on<br> </font></i> Parking brake released - light off<br> Check wire connected to warning switch in engine compartment<br> See "Basic Hydraulic Test", below in this chart<br> <font color="#00FF00"><i> </i> <i> Warning light off<br> </i></font> Check and repair electrical circuit as required<br> <b>Basic Hydraulic Test<br> </b> Ignition in Run position, pump brakes five times with engine off. Then apply brake pedal <u>very slowly</u>.<br> Gradually increase pedal effort while watching warning light, increase to very high effort (both feet),<br> hold heavy effort for 30 seconds, release pedal slowly.<br> <font color="#FFFF00"><i> Warning light comes on with moderate pedal effort and stays on when pedal is released<br> </i></font> Master cylinder has internal leak, replace and bleed brakes<br> <i><font color="#FFFF00"> Warning light comes on at moderate to heavy pressure but goes out when pedal is released<br> </font></i> Air in system. the greater pedal effort required to get the light on, the less air in the system,<br> bleed brakes<br> <font color="#FFFF00"><i> Warning light does not come on - system has no defect!</i></font><br> Bleeding or adjusting rear brakes may make some improvement. If less than 1000 miles on<br> car, additional mileage will help. If pedal pumps up but becomes low after left or right turns,<br> loose front wheel bearings may be the problem.<br> <font color="#FFFF00"><i> Warning light comes on only after holding heavy pedal effort for several seconds, and pedal<br> moves down under constant heavy effort<br> </i></font> Small high pressure leak in system. Repeat test several times and look for wet area.<br> Repair and bleed.</font> <p><b><a name="C3">Brake</a> Chart 3 - Troubleshooting Power Brake Diagnosis</font></b> (<a href="#GUIDE">back to Diagnosis Guide</a>)</font><p><b><a name="C4">Brake</a> Chart 4 - Brake Noise Diagnosis</b></font><p><b>Engine Noise Location</b></font><p><b><a name="C5">Brake</a> Chart 5 - Wheel Brakes Diagnosis</b></font><p>Road Test Car<br> <i><font color="#FFFF00"> Pulls during normal braking<br> </font></i> See <a href="#C6">Chart 6</a>.<br> <font color="#FFFF00"><i> Pulls with no braking or with very heavy braking<br> </i></font> See "Front Suspension" section of service manual.<br> <font color="#FFFF00"><i> Excessive pedal travel after turns<br> </i></font> Loose front wheel bearings<br> <font color="#FFFF00"><i> Grabby brakes<br> </i></font> Contaminated lining<br> <i><font color="#FFFF00"> Pedal pulses, car surges during braking, brake chatter<br> </font></i> Disconnect and plug master cylinder outlet to rear brakes<br> <i><font color="#00FF00"> Surging or pulsing still present<br> </font></i> Inspect front brakes for disc thickness variation and runout, check bearing adjustment<br> <font color="#00FF00"><i> No vibration or pulsing<br> </i></font> Inspect rear brakes for out of round *<br> * Pulsation caused by rear brakes may be eliminated or reduced by indexing drum (rear) two studs on<br> axle flange</font><p><b><a name="C6">Brake</a> Chart </b><b>6 - Brake Pull Diagnosis</b></font><p><b>Vehicle Pulls to One Side During Normal (Light) Braking<br> </b> Check for unequal front brake drag, open and close bleeders and recheck<br> <i><font color="#FFFF00"> Inspect front end for looses attachments, including steering gear mounting bolts and worn or<br> damaged bushings<br> </font></i> Inspect front brakes<br> <font color="#00FF00"><i> No problems<br> </i></font> Inspect front end height and cross shaft adjustment<br> <font color="#00FFFF"><i> No problems<br> </i></font> Replace front linings<br> Plug rear brakes and road test front brakes only<br> <i><font color="#FFCC99"> Still pulls<br> </font></i> Re-evaluate symptoms<br> <font color="#CCCCFF"><i> Pulls or leads with no brakes, pulls on <u>hard</u> braking only<br> </i></font> See "Front Suspension" section of service manual.<br> <font color="#FFCC99"><i> No pull<br> </i></font> Inspect rear brakes & parking brake. Repair as required<br> <font color="#00FFFF"><i> Defects or problems found<br> </i></font> Repair as required<br> <i><font color="#00FF00"> Grease on rotors, fluid leaks, damage<br> </font></i> Repair as required<br> <i><font color="#FFFF00"> Drag affected by hydraulic pressure<br> </font></i> See <a href="#C1">Chart 1</a> and <a href="#C5">Chart 5</a><br> Repair or replace as required<br> <i><font color="#FFFF00"> Unequal drag<br> </font></i> Check calipers, pry back pistons, adapter ways, etc<br> Repair or replace caliper</font><p><b>Make sure that whenever a brake part is replaced or a brake repair is completed, the vehicle is</b><br> <b>road tested.</b></font><p> </td><td valign="top" width="24"></td><td valign="top" width="1%"> <table border="0" cellpadding="0" cellspacing="0" width="100%"><tr><td> </td> </tr> <tr> <td width="250"><table border="1" cellspacing="1" width="100%" bgcolor="#52ABD6"> <tr> <td width="25%" bgcolor="#000000"> <p align="center"><a href="../index.html"><b>HOME</b></a><br> <nobr><a href="sm05b.html">Next</a></nobr><br><a href="../tools/whatsnew.html">New</a><br> <a href="../tools/sitemap.html">Map</a></font></td> <td width="75" bgcolor="#000000"><nobr><a href="sm05.html">Up</a></nobr><br><nobr>Service Adjustments</nobr><br><nobr><a href="sm05b.html">Drum Brakes</a></nobr><br><nobr><a href="sm05c.html">Master Cylinder</a></nobr><br><nobr><a href="sm05d.html">Hydraulic System Control Valves</a></nobr><br><nobr><a href="sm05e.html">Wheel Cylinders</a></nobr><br><nobr><a href="sm05f.html">Parking Brakes</a></nobr><br><nobr><a href="sm05g.html">Power Brakes (Bendix)</a></nobr><br><nobr><a href="sm05h.html">Disc Brakes</a></nobr><br><nobr><a href="sm05i.html">Braking Disc (Rotor)</a></nobr> </font></td> </tr> </table></td> <td width="375"><div style="text-align:center;"> <script async src="//pagead2.googlesyndication.com/pagead/js/adsbygoogle.js"></script>  <ins class="adsbygoogle" style="display:block" data-ad-client="ca-pub-7865546952023728" data-ad-format="auto"></ins> <script> (adsbygoogle = window.adsbygoogle || []).push({}); </script> </div> <p align="center" style="font-size: small;"><img src="/graphic/site/bigdip_small.jpg" alt="Dodge Diplomat" width="100" height="26"><br> • Copyright © <script>document.write(new Date().getFullYear())</script> VerticalScope Inc. 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