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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Dodge Sprinter 2500 car and truck
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Power Brake Units -> Description
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
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...
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Disc Brakes -> Brake Pad Service -> Caravan, Town & Country & Voyager -> Commander -> Dakota & Durango -> Front -> Full Size Pickup -> Grand Cherokee, Liberty & Wrangler -> Inspection -> Installation -> Pacifica -> PT Cruiser -> Rear -> Removal -> Sprinter
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Caravan, Town & Country & Voyager
Front
Removal
- Raise and support vehicle.
- Remove front wheel and tire assemblies.
- Remove two caliper-to-knuckle attaching bolts, then remove caliper by sliding away from adapter and lifting off rotor, Fig. . Support caliper firmly to prevent weight of caliper from damaging flexible hose.
- Remove outboard pad by prying pad retaining clip over raised area of caliper, then sliding pad down and off of caliper.
- Pull inboard pad away from caliper piston, until springs release from piston.
Installation
- Inspect piston seal for leaks and for ruptures in piston du...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 2500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Power Brake Units -> Power Brake Unit Service -> Caravan, Town & Country & Voyager -> Commander -> Dakota & Durango -> Full Size Pickup -> Grand Cherokee -> Hydraulic Booster -> Installation -> Liberty -> Pacifica -> PT Cruiser -> Removal -> Replacement -> Sprinter -> Vacuum Booster -> Wrangler
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
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...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 2500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Disc Brakes -> Tightening Specifications
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 2500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Disc Brakes -> Troubleshooting -> Brake Chatter -> Brake Drag -> Brake Fade -> Brake Pull -> Brake Squeal Or Squeak -> Hard Pedal Or High Pedal Effort -> Low Pedal -> Pedal Falls Away -> Pedal Pulsation -> Rear Brake Grab Or Pull -> Spongy Pedal
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Pedal Falls Away
- System leak at brake line, fitting, hose or caliper/wheel cylinder.
- Internal leakage in master cylinder caused by worn or damaged piston cups.
- Internal leak in ABS or RWAL system.
Low Pedal
- Worn brake linings.
- Worn drums or rotors.
- Rear brakes out of adjustment.
Spongy Pedal
- Air in hydraulic system.
- Thin brake drums.
- Substandard brake lines and hoses.
Hard Pedal Or High Pedal Effort
- Linings that are water soaked, contaminated or glazed.
- Faulty power booster or check valve.
Pedal Pulsation
- Disc brake rotors have excessive lateral runout or thickness variation.
- Out of round brake ...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 2500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 2500 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Adjustments -> Height Sensing Proportioning Valve -> Park Brake Cable Tensioner -> Stop Lamp Switch
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
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...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 2500 BRAKE SERVICE PROCEDURES
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