2004 Dodge Durango Brake Service (ONLINE REPAIR MANUALS)

Height Sensing Proportioning Valve

On these models the proportioning valve is not adjustable. Do not attempt to make adjustments.

Stop Lamp Switch

• Push and hold brake pedal in applied position.
• Push switch forward until fully seated against bracket.
• Release brake pedal.
• Lightly pull brake pedal rearward until master cylinder pushrod bottoms against master cylinder internal stop. This action will set switch plunger at proper stroke length.

Park Brake Cable Tensioner

Tensioner adjustment is only required when the tensioner, or a cable has been replaced or disconnected for service. To avoid fa...

These self contained vacuum hydraulic power braking units are of the vacuum suspended type. They use engine intake manifold vacuum or a vacuum pump along with atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, with integral vacuum power diaphragms, controls the degree of brake application or release depending on amount of foot pressure applied to...

When wheel slip is detected during a brake application, the ABS enters anti-lock mode. During anti-lock braking, hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold, or increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase hydraulic pressure above the amount which is transmitted by the master cylinder during braking.

During anti-lock braking, a series of rapid pulsations is felt in the brake pedal...

The only serviceable power brake booster components are the vacuum hose and the check valve. The power brake booster must be serviced as an assembly. If diagnosis indicates a power brake booster fault condition, the unit must be replaced as an assembly.

Replacement

Caravan, Town & Country & Voyager

• With engine stopped, pump brake pedal four or five times to deplete power booster vacuum.
• Disconnect both battery cables, then remove battery thermo guard and battery from tray.
• Remove air inlet resonator and hoses as an assembly from throttle body and air cleaner housing.
• Remove c...

Caravan, Town & Country & Voyager

• Raise and support vehicle, then remove wheel and caliper as outlined under . Support caliper at all times to prevent brake hose damage.
• Slide brake rotor off hub.
• Reverse procedure to install. Clean brake rotor with alcohol or other suitable solvent.

Commander

Front

• Raise and support vehicle using suitable lift or jack.
• Remove tire and wheel assembly.
• Remove caliper as outlined in .
• Secure caliper anchor assembly using suitable wire.
• Remove and discard O-ring securing disc brake rotor on hub.
• Remove rotor from hub and bearing.
• Reverse procedure to install, n...

Brake Shoe, Replace

Do not intermix automatic adjuster components from side to side.

9, 10, 11 & 13 Inch Drums

Caravan, Dakota, Town & Country & Voyager

Removal

• Raise and support vehicle, then remove rear wheels.
• Remove drum retaining nuts if equipped, then the drums. If drum will not separate from brake shoes or axle, proceed as follows:
• Ensure parking brake is disengaged.
• Remove adjuster hole plug from backing plate.
• Insert small screwdriver or equivalent, through adjuster hole, then push and hold self adjuster lever off adjuster screw assembly, Fig. .
• Back off adjuster screw assembly unt...