2006 Dodge Durango Brake Service (ONLINE REPAIR MANUALS)

Master Cylinder/Power Booster Test

• Start engine and inspect booster vacuum hose connections for leaks.
• Stop engine and shift transmission into neutral.
• Pump brake pedal until all vacuum reserve in booster is depleted.
• Press and hold brake pedal under light foot pressure. Pedal should hold firm. If it falls away master cylinder is faulty.
• Start engine and note pedal action. Pedal should fall away slightly under light foot pressure, then hold firm.
• If no pedal action is felt, the power booster, vacuum supply or vacuum check valve are faulty. Proceed to "Power Booster Vacuum Test."
• If p...

Brake Drums

Any time the brake drums are removed for brake service, the braking surface diameter should be inspected with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor sc...

Service Brake

Except FWD Models

Self-Adjusting Brakes

These brakes have self-adjusting shoe mechanisms that ensure correct lining to drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward.

Although the brakes are self-adjusting, an initial adjustment is required when the brake shoes have been relined, replaced or when the length of the star wheel adjuster has been changed during some other service operation.

Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the aut...

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...

Master Cylinder

Except Caravan, Town & Country & Voyager

The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir is the only serviceable component.

The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. The equalization feature does not affect circuit separation in the event of a front or rear brake fault. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit.

Caravan, Town & Country...

General Service Precautions

Certain components of the anti-lock brake system are not intended to be serviced individually. Attempting to remove or disconnect components of this type may result in personal injury and/or improper system operation. Only the components with removal and installation procedures should be serviced.

Observe the following general precautions when servicing the anti-lock b...