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Dodge Viper SRT-10 (ZB). Manual - part 36

(2) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(3) Remove wheel and tire assembly. (Refer to 22 -

TIRES/WHEELS - REMOVAL)

(4) Remove brake flex hose banjo bolt. Remove

brake flex hose and seal washers from caliper along
with banjo bolt. Discard washers.

(5) Remove two bolts attaching hydraulic brake

caliper to knuckle (Fig. 31).

(6) Remove hydraulic brake caliper from knuckle.

DISASSEMBLY

Except for piston size, rear calipers are same

design as front calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPER -
FRONT - DISASSEMBLY)

ASSEMBLY

Except for piston size, rear calipers are same

design as front calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPER -
FRONT - ASSEMBLY)

INSTALLATION

(1) If brake shoes need to be installed in caliper

before installation, (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/BRAKE

PADS/SHOES

INSTALLATION)

(2) Install brake caliper on steering knuckle (Fig.

31). Install brake caliper mounting bolts and tighten
to 115 N·m (85 ft. lbs.) torque.

CAUTION: When the brake flex hose is installed on
the caliper, NEW copper seal washers MUST be
used.

(3) Install brake flex hose on brake caliper as fol-

lows:

(a) Place NEW copper seal washers on each side

of banjo fitting located on end of flex hose.

(b) Install banjo bolt through washers and banjo

fitting, into threaded caliper hose port. Only hand
tighten the flex hose to caliper assembly banjo bolt
do not torque. Tighten banjo bolt to 31 N·m (23 ft.
lbs.) torque.
(4) Install wheel and tire assembly (Refer to 22 -

TIRES/WHEELS - INSTALLATION). Progressively
tighten wheel mounting nuts in proper sequence to
122 N·m (90 ft. lbs.) torque.

(5) Lower vehicle.
(6) Remove brake pedal holding tool.

CAUTION: Before moving vehicle, pump brake
pedal several times to ensure vehicle has a firm
brake pedal to adequately stop vehicle.

(7) Bleed brakes as necessary. (Refer to 5 -

BRAKES - STANDARD PROCEDURE)

(8) Road test vehicle making several stops to wear

off any foreign material on brakes and to seat brake
shoes. New brake shoes need to be properly bur-
nished. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE

PADS/SHOES

STANDARD

PROCEDURE).

Fig. 30 Brake Pedal Holding Tool Installed

1 - BRAKE PEDAL HOLDING TOOL
2 - ACCELERATOR PEDAL
3 - SEAT
4 - BRAKE PEDAL
5 - CLUTCH PEDAL

Fig. 31 Rear Brake Caliper And Rotor Mounting

1 - HUB AND BEARING
2 - KNUCKLE
3 - CALIPER
4 - ROTOR

5 - 22

BRAKES - BASE

DISC BRAKE CALIPER - REAR (Continued)

FLUID

DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION

CAUTION: The hydraulic fluid used in automotive
brake systems is hygroscopic. This means that the
hydraulic fluid tends to absorb moisture from the
atmosphere over a period of time. As hydraulic
brake fluid absorbs moisture, it effects the function
of the vehicles hydraulic brake system. For this rea-
son the vehicles hydraulic brake fluid should be
drained and replaced using fresh clean hydraulic
brake fluid every two years. When replacing hydrau-
lic brake fluid use only Mopar

brake fluid or an

equivalent from a sealed container. This vehicle
comes with, and the manufacturer recommends,
brake fluid conforming to DOT 4 specifications. If
DOT 4 brake fluid is not available, DOT 3 brake fluid
is fully compatible with DOT 4, and can be substi-
tuted in its absence. (Refer to 5 - BRAKES - STAN-
DARD PROCEDURE).

Indications of fluid contamination in the brake sys-

tem are swollen or deteriorated rubber parts.

Swollen rubber parts indicate the presence of

petroleum in the brake fluid.

To test for contamination, put small amount of

drained brake fluid in a clear glass jar. If the fluid sep-
arates into layers, there is mineral oil contamination.

If contaminated, drain and thoroughly flush the

system. Replace the master cylinder, proportioning
valve, caliper seals and all hoses.

STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING

Check the brake fluid level in the master cylinder

reservoir a minimum of twice a year.

The brake fluid reservoir is marked FULL and

ADD indicating the allowable brake fluid level range
in the reservoir (Fig. 32).

Although there is a range, the preferred level is at

the FULL mark. If necessary, adjust the brake fluid
to the Full mark on the side of the master cylinder
fluid reservoir using Mopar

t Brake & Clutch Fluid

DOT 4 Motor Vehicle from a sealed container. Do not
overfill the system. Use only brake fluid that has
been stored in a tightly-sealed container. This vehi-
cle comes with, and the manufacturer recom-
mends,

brake

fluid

conforming

DOT

specifications. If DOT 4 brake fluid is not avail-
able, Mopar

t Brake Fluid DOT 3 Motor Vehicle

is fully compatible with DOT 4, and can be sub-
stituted in its absence. However, DOT 3 brake
fluid generally has a lower boiling point than
DOT 4, and is not recommended for high per-
formance applications.

CAUTION: DO NOT use brake fluid with a lower
boiling point. Brake failure can result during pro-
longed hard braking.

CAUTION:

NOT

use

petroleum-based

fluid

because seal damage in the brake system will
result.

SPECIFICATIONS

BRAKE FLUID

This vehicle comes with, and the manufacturer rec-

ommends, brake fluid conforming to DOT 4 specifica-
tions. Use Mopar

t Brake & Clutch Fluid DOT 4

Motor Vehicle from a tightly sealed container.

If DOT 4 brake fluid is not available, Mopar

Brake Fluid DOT 3 Motor Vehicle is fully compatible
with DOT 4, and can be substituted in its absence.
However, DOT 3 brake fluid generally has a lower
boiling point than DOT 4, and is not recommended
for high performance applications.

Any brake fluid used in this vehicle must conform

to a minimum DOT 3 specifications and SAE J1703
standards. No other types of brake fluid are recom-
mended or approved for usage in the vehicle brake
system.

Fig. 32 Master Cylinder And Booster

1 - MASTER CYLINDER
2 - MASTER CYLINDER MOUNTING NUT
3 - POWER BRAKE BOOSTER

BRAKES - BASE

5 - 23

CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.

CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids are
items such as engine oil, transmission fluid, power
steering fluid etc.

MASTER CYLINDER

STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING

CAUTION: When clamping the master cylinder in a
vise for bleeding, carefully tighten the vise just
enough to hold the master cylinder from moving.
Excessive pressure can damage the master cylin-
der.

(1) Clamp master cylinder in a vise.

NOTE: The master cylinder outlet ports use ISO
style flares and metric threads. Special Tool Pack-
age 8822 includes ISO style flare adapters with met-
ric threads to be used in conjunction with Bleeder
Tubes, Special Tool Package 8358.

(2) Attach special tools for bleeding master cylin-

der in the following fashion:

(a) Thread Adapter, Special Tools 8822–1, into

the primary outlet port. Tighten Adapter to 17 N·m
(145 in. lbs.) torque.

(b) Thread Adapter, Special Tool 8822–2, into the

secondary outlet port. Tighten Adapter to 17 N·m
(145 in. lbs.) torque.

one

Bleeder

Tube,

Special

Tool

8358–1, into each Adapter. Tighten each tube to 17
N·m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 33).

NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level to avoid ingesting air while bleeding.

(3) Fill reservoir with brake fluid conforming to

DOT 4 Mopar

t Brake Fluid or equivalent. If DOT 4

is not available, DOT 3 is acceptable. Make sure fluid
level is above tips of bleeder tubes in reservoir.

(4) Using a wooden dowel (Fig. 33), depress master

cylinder pistons slowly, then allow pistons to return
to released position. Repeat several times until all air
bubbles are expelled. Make sure fluid level stays
above tips of bleeder tubes in reservoir while bleed-
ing.

(5) Remove bleeder tubes and adapters from mas-

ter cylinder. Plug master cylinder outlets and install
filler cap.

(6) Remove master cylinder from vise and install

on power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER

CYLINDER

INSTALLATION)

REMOVAL

NOTE: Review all Warnings and Cautions. (Refer to
5 - BRAKES - WARNING)

(1) With the engine not running, pump the brake

pedal several times to remove all vacuum from power
brake booster.

(2) Open hood.
(3) Disconnect battery negative (-) terminal.
(4) Disconnect brake fluid level switch wiring con-

nector (Fig. 34).

Fig. 33 Master Cylinder Set Up For Bleeding

(Typical)

1 - BLEEDER TUBES 8358-1
2 - WOODEN DOWEL
3 - ADAPTER 8822-1
4 - ADAPTER 8822-2

5 - 24

BRAKES - BASE

FLUID (Continued)

(5) Disconnect primary and secondary brake tubes

from master cylinder housing (Fig. 34). Install plugs
at brake tube outlets.

(6) Remove two nuts attaching master cylinder to

power brake booster.

(7) Slide master cylinder straight out and away

from booster.

INSTALLATION

NOTE: It is not always necessary to bleed the entire
hydraulic system after replacing the master cylin-
der, provided that the master cylinder has been
filled and properly bled prior to installation. The
entire system should only need to be bled if air or
contamination in the system is suspected.

(1) Bleed master cylinder assembly. (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - STANDARD PROCEDURE)

(2) Wipe face of booster clean where master cylin-

der seal comes in contact when installed. Do not get
any cleaner or debris inside booster.

(3) Position master cylinder on mounting studs of

booster. Be sure push rod on booster is correctly
aligned with piston of master cylinder.

(4) Push master cylinder up against front of

booster.

(5) Install master cylinder mounting nuts and

tighten to 28 N·m (250 in. lbs.) torque.

(6) Connect brake tubes to master cylinder pri-

mary and secondary ports (Fig. 34). Tighten fittings
to 17 N·m (145 in. lbs.) torque.

(7) Connect the brake fluid level switch wiring

connector (Fig. 34).

(8) Connect battery negative terminal.
(9) Fill reservoir to proper level with brake fluid.
(10) Road test vehicle to ensure proper operation

of brakes.

PEDALS - ADJUSTABLE

DESCRIPTION

The brake pedal on this vehicle is included in an

assembly known as the adjustable pedals assembly.
The adjustable pedals assembly includes the clutch,
brake and accelerator pedals.

This switch operated assembly is designed to

enable fore and aft repositioning of the clutch, brake
and accelerator pedals. This results in improved
ergonomics in relation to the steering wheel for taller
and shorter drivers. Being able to adjust the pedal
positions also allows the driver to set steering wheel
tilt and seat position to the most comfortable posi-
tion. The effort required for pedal application will not
change regardless of pedal position. All three pedals
adjust at the same time.

The adjustable pedals assembly is serviced as a

complete assembly.

REMOVAL

NOTE: Review all Warnings and Cautions. (Refer to
5 - BRAKES - WARNING)

(1) Disconnect battery negative (-) cable from bat-

tery and isolate.

(2) Access and remove steering column from vehi-

cle.

(Refer

STEERING/COLUMN

REMOVAL)

(3) Remove brake lamp switch and discard. Do

not reuse switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING

EXTERIOR/BRAKE

LAMP

SWITCH - REMOVAL)

Fig. 34 Master Cylinder

1 - MASTER CYLINDER
2 - WIRING CONNECTOR
3 - PRIMARY BRAKE TUBE
4 - SECONDARY BRAKE TUBE
5 - BRAKE FLUID LEVEL SWITCH

BRAKES - BASE

5 - 25

MASTER CYLINDER (Continued)

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