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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Brake System Bleed -> Manual -> Master Cylinder -> Pressure
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Manual
- Remove reservoir filler caps and fill reservoir with proper brake fluid.
- If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.
- Close each bleed screw as fluid starts to drip from them.
- Fill master cylinder reservoir once more before proceeding.
- Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid, Fig. . Ensure bleed hose is immersed in fluid.
- Open up bleeder, then have an assistant press down brake pedal.
- Once brake pedal is down, close bleeder. Repeat bleeding unt...
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 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 3500 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 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 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 3500 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 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Component Replacement -> Caravan, Town & Country & Voyager -> Except Caravan, Town & Country & Voyager -> Master Cylinder
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Master Cylinder
Except Caravan, Town & Country & Voyager
- With engine off, pump brake pedal five times to deplete vacuum in brake booster.
- Siphon fluid from brake reservoir.
- On Wrangler models, remove evaporative canister.
- On PT Cruiser models, remove air cleaner housing, then disconnect power distribution center and position aside.
- On all models, disconnect low fluid switch electrical connector.
- Remove brake lines from master cylinder.
- Remove master cylinder mounting nuts.
- On Durango models with ESP, remove inner fender well, then remove integrated power module (IPM) fasteners and ...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 cars and light trucks from 1990+.
Disc Brakes -> Brake System Bleed -> Manual -> Master Cylinder -> Pressure
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Manual
- Remove reservoir filler caps and fill reservoir with proper brake fluid.
- If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.
- Close each bleed screw as fluid starts to drip from them.
- Fill master cylinder reservoir once more before proceeding.
- Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid, Fig. . Ensure bleed hose is immersed in fluid.
- Open up bleeder, then have an assistant press down brake pedal.
- Once brake pedal is down, close bleeder. Repeat bleeding unt...
CLICK HERE TO GET FULL ACCESS TO 2004 Dodge Sprinter 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Dodge Sprinter 3500 cars and light trucks from 1990+.
Disc Brakes -> Precautions -> Brake Bleed -> Brake Disc Service -> Brake Lines & Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Brake Lines & Linings
Remove one of the front wheels and inspect the brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if required.
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective pad is worn or damaged. Inspect and, if required, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of ...
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