The Necessary Evil
Join Date: Aug 2006
SOP, Cautions and Warnings
WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.
To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar® Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals.
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors.
If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle.
Measure brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter (0.04 inches) or less.
NOTE: It is important to inspect both front and rear brake pads during the same inspection. Typically, front and rear brake pads wear out at the same time.
Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics.
If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from.
CAUTION: Do not use petroleum-based fluid because seal damage in the brake system will result. The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar® Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container.
CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
CAUTION: Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing mineral oil to clean system components. These fluids damage rubber cups and seals.
CAUTION: During service procedures, grease or any other foreign material must be kept off the caliper assembly, brake linings, brake rotor and external surfaces of the hub.
CAUTION: When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and caliper, and scratching or nicking the brake shoe lining.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container will absorb moisture from the air and contaminate the fluid.
The antilock brake system uses an electronic control module known as the Antilock Brake Module (ABM). This module is designed to withstand normal current draws associated with vehicle operation. Care must be taken to avoid overloading the circuits.
CAUTION: In testing for open or short circuits, do not ground or apply voltage to any of the circuits unless instructed to do so for a diagnostic procedure.
CAUTION: These circuits should only be tested using a high impedance multi-meter or the designated scan tool as described in this section. Power should never be removed or applied to any control module with the ignition in the ON position. Before removing or connecting battery cables, fuses, or connectors, always turn the ignition to the OFF position.
CAUTION: The ABM 47-way connector should never be connected or disconnected with the ignition switch in the ON position.
CAUTION: This vehicle utilizes active wheel speed sensors. Do not apply voltage to wheel speed sensors at any time.
CAUTION: Use only factory wiring harnesses. Do not cut or splice wiring to the brake circuits. The addition of aftermarket electrical equipment (car phone, radar detector, citizen band radio, trailer lighting, trailer brakes, etc.) on a vehicle equipped with antilock brakes may affect the function of the antilock brake system.
CAUTION: When performing any service procedure on a vehicle equipped with ABS, do not apply a 12-volt power source to the ground circuit of the pump motor in the HCU. Doing this will damage the pump motor and will require replacement of the entire HCU.
CAUTION: An attempt to remove or disconnect certain system components may result in improper system operation. Only those components with approved removal and installation procedures in this manual should be serviced.
CAUTION: If welding work is to be performed on the vehicle using an electric arc welder, the ABM connector should be disconnected during the welding operation.
CAUTION: Many components of the ABS are not serviceable and must be replaced as an assembly. Do not disassemble any component which is not designed to be serviced.
CAUTION: Only the recommended jacking or hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle.
1. Raise and support the vehicle.
2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
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