Bulletin BPI-96

Bulletin BPI 00-02 DODGE, DURANGO Subject: Brake Grind Or Growl Sound Vehicle Involved: 1998-99 DODGE DURANGO Condition: Growl/grind noise that may be accompanied by squeal. Low frequency grinding noise that may be accompanied by pedal pulsation. In addition, wheel and seat vibration may occur in extreme cases. Repair Procedure: 1. Clean master cylinder reservoir and filler caps. 2. Remove the reservoir filler cap and remove approximately ¼ 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, remove front wheel and tire assemblies. 4. Open caliper bleed screws, bottom the caliper pistons in the caliper bores using a large c- clamp. Close the caliper bleed screw. 5. Remove the caliper slide pins and remove caliper from the 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. 6. Remove the inboard and outboard brake pads, clean and lubricate all pad and caliper contact points. 7. Remove any dirt or foreign material from the wear surface of the rotor. 8. Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 1” inward from the rotor’s edge. If the rotor exceeds .004 inch runout, resurface or replace the rotor. Refer to machining specifications guide. 9. Position a micrometer approximately 1” in from the outer circumference and measure the thickness. Take additional 6-12 measurements around the rotor. If the thickness of the rotor varies more than .0005 inch resurface or replace the rotor. Refer to machining specifications guide. 10. Install a new inboard brake pad and outboard pad making sure the anti-rattle clips are attached correctly. 11. Install caliper and brake pad assembly over the rotor and into the adapter. It is very important for the brake pad tangs to be properly clinched on the adapter ledge. 12. Install and tighten the caliper slide pins to (18 –26 ft.-lbs.) 13. Start the slide pins by hand before tightening. Do not cross thread the pins. 14. Install the wheel and tire assembly and lower the vehicle. Brake Parts Inc. 4400 Prime Parkway McHenry, IL 60050 (815) 363-9000 ® Raybestos is a Registered Trademark licensed to Brake Parts Inc. by Raybestos Products Company. 15. Pump the brake pedal to seat the new brake pads and verify a firm brake pedal before moving the vehicle. 16. Fill master cylinder reservoir to the proper level as indicated on the side of the Reservoir and flush the hydraulic brake system. 17. Repeat the diagnostic procedure to ensure that the brake growl/grind noise has been eliminated. LUBRICATE .

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