Repair Procedure

1. Raise the vehicle on a suitable hoist.

2. Remove both rear wheel and tire assemblies.

3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum.





4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).

5. Lower the vehicle so that it is low enough to access the brake pedal.

6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder.

7. Raise the vehicle.





8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)

9. Remove the adjustment lever from the leading brake shoe.

10. Remove the brake shoe lower return springs.





11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3)

12. Remove the brake shoe to brake shoe upper return spring.

13. Remove the trailing brake shoe assembly hold down spring and pin.





14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4)

15. Remove the automatic adjuster assembly from the leading shoe.

16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly.

17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe.

18. Disconnect the park brake cable from the park brake actuation lever.

19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first.

CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.





20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)

21. Disconnect the brake tube from the wheel cylinder.

22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle.

23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.

CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE.





24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25.

a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool.

b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle.

c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1.

d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26.





25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7)

a. Thread threaded guide pins into hub and bearing mounting holes.

b. Remove the two outboard spring plate bolts.

c. Using the spring plate bolts, install the screw mount, special tool 8458-2.

d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.

e. Place a dab of grease in the dimple of the push plate.

f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw.

g. Remove the tool.

h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).

26. Remove the hub/bearing from the rear axle and brake support plate.

27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate.

28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.

29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle.

30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle.

31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).

NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED.

32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate.

33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.).

34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)

35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.).

36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.

37. Install the rear park brake cable into its mounting hole in the brake support plate.

38. Install the park brake cable to the park brake actuator lever.

39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269.

40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.

41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut.

42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate.

43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.

44. Install the upper brake shoe to brake shoe return spring.

CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED.

45. Install the tension clip attaching the upper return spring to the automatic adjuster.

46. Install the lower brake shoe to brake shoe return springs.

47. Install the automatic adjuster lever on the leading brake shoe.

48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.

49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly.

50. Repeat steps 8 through 48 for the other side rear brake assembly.

51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable.

52. Adjust the rear brakes so they do not interfere with installing the brake drums.

53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement.

54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.).

55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.

56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring.

57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned.

58. Install the adjusting/inspection hole rubber plug(s) saved in step 26

59. Repeat steps 55 through 58 for the other side rear brake.

60. Perform the base brake bleeding procedure described in the appropriate service manual.

61. Lower the vehicle to the floor.

62. Push the park brake pedal down fully and release to adjust the park brake cables.