2006 Dodge Sprinter 2500 Brake Service (ONLINE REPAIR MANUALS)

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...

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...

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 ...

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...

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...

Brake System Bleed

The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module.

Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir.

T...