Dodge Sprinter. Manual - part 26

CLEANING - REAR DRUM IN HAT BRAKE

Clean the individual brake components, including

the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.

INSTALLATION

INSTALLATION - (SRW)

NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.

(1)

Ensure that the cable lock moves easily

before installing shoes.Install the park brake
shoes.

(2) Install the lower retracting spring using special

tool 9280.

(3) Install the hold down springs using special tool

9281.

(4) Install the upper retracting spring using spe-

cial tool 9280.

(5) Install the adjuster.
(6) Install the front park brake cable to the pulley

unit.

(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.

(10) Lower the vehicle.
(11) Pump the brake pedal several times to check

the operation of the brakes before moving vehicle.

INSTALLATION - (DRW)

NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.

(1)

Ensure that the cable lock moves easily

before installing shoes.Install the park brake
shoes.

(2) Install the lower retracting spring.
(3) Install the pressure hold down springs by

depressing with your fingers and twisting to lock in
place.

(4) Install the upper retracting spring.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley

unit.

(7) Install the disc brake rotor.
(8) Install the rear wheel flange ring. Tighten to

200 N·m (148 ft. lbs.).

(9) Install the rear wheels.
(10) Adjust the parking brakes.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to check

the operation of the brakes before moving vehicle.

ADJUSTMENTS

ADJUSTMENT

(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Turn the adjusting wheel through the hole of

the wheel lug bolt until it is no longer possible to
rotate the rear wheel (Fig. 38).

(4) Loosen the adjusting wheel 3-4 teeth divisions

(Fig. 38).

Fig. 37 PARK BRAKE SHOES WITH DUAL REAR

WHEELS

1 - HOLD DOWN PIN
2 - PRESSURE SPRING
3 - ADJUSTER
4 - UPPER RETRACTING SPRING
5 - LOWER RETRACTING SPRING
6 - CABLE LOCK
7 - LOCKING PIN
8 - BRAKE CABLE
9 - PARK BRAKE SHOE

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BRAKES - BASE

(5) Inspect the clearance, or a slight drag when

rotating the wheel/rear disc brake rotor (Fig. 39).

(6) Install rear wheels.
(7) Lower the vehicle and test the park brake sys-

tem to hold the vehicle.

Fig. 38 STAR WHEEL ADJUSTER

1 - LEFT HAND PARK BRAKE SHOES APPLIED
2 - RIGHT HAND PARK BRAKE SHOES RELEASED
3 - FLAT BLADED TOOL

Fig. 39 ADJUSTING REAR PARK BRAKE SHOES

1 - FRONT BRAKE CABLE
2 - SHOE ADJUSTER
3 - REAR BRAKE CABLES
4 - PARK BRAKE CABLE ADJUSTER

BRAKES - BASE

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BRAKES - ABS

TABLE OF CONTENTS

page

BRAKES - ABS

SPECIFICATIONS - TORQUE CHART

. . . . . . . . 30

ELECTRICAL

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 30

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FRONT WHEEL SPEED SENSOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 31

REAR WHEEL SPEED SENSOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

TONE WHEEL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

STEERING ANGLE SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 33

LATERAL ACCELERATION SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 33

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 34

YAW RATE SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 35

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 36

HCU (HYDRAULIC CONTROL UNIT)

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 36

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 37

BRAKES - ABS

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Brake Lines To Hydraulic

unit

—

ELECTRICAL

DESCRIPTION

NOTE: Wheel speed sensor should be installed all
the way into the clamping bushings, the wheel
speed sensor will self adjust when the vehicle is
moved.

The ABS brake system uses 4 wheel speed sensors.

A sensor is mounted to each front hub/bearings in
the front. A rear sensor is mounted to each rear sup-
port plate.

OPERATION

The Wheel Speed Sensor consists of a magnet sur-

rounded by windings from a single strand of wire.
The sensor sends a small AC signal to the CAB. This
signal is generated by magnetic induction. The mag-

netic induction is created when a toothed sensor ring
(exciter ring or tone wheel) passes the stationary
magnetic WSS.

When the ring gear is rotated, the exciter ring

passes the tip of the WSS. As the exciter ring tooth
approaches the tip of the WSS, the magnetic lines of
force expand, causing the magnetic field to cut across
the sensor’s windings. This, in turn causes current to
flow through the WSS circuit (Fig. 1) in one direc-
tion. When the exciter ring tooth moves away from
the sensor tip, the magnetic lines of force collapse
cutting the winding in the opposite direction. This
causes the current to flow in the opposite direction.
Every time a tooth of the exciter ring passes the tip
of the WSS, an AC signal is generated. Each AC sig-
nal (positive to negative signal or sinewave) is inter-
preted by the CAB. It then compares the frequency of
the sinewave to a time value to calculate vehicle
speed. The CAB continues to monitor the frequency

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BRAKES - ABS

to determine a deceleration rate that would indicate
a possible wheel-locking tendency.

The signal strength of any magnetic induction sen-

sor is directly affected by:

• Magnetic field strength; the stronger the mag-

netic field, the stronger the signal

• Number of windings in the sensor; more wind-

ings provide a stronger signal

• Exciter ring speed; the faster the exciter ring/

tone wheel rotates, the stronger the signal will be

• Distance between the exciter ring teeth and

WSS; the closer the WSS is to the exciter ring/tone
wheel, the stronger the signal will be.

FRONT WHEEL SPEED SEN-
SOR

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Pull the wheel speed sensor out of the front

wheel hub (Fig. 2).

(4) Only do this step if sensor replacement is

necessary. Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 2).

(5) Remove clamping sleeve from the knuckle if

damaged or being replaced with new sensor (Fig.
2).

INSTALLATION

(1) Connect separate wheel speed sensor cables

with shrink-fit sleeves and shrink-fit tubing (Fig. 2).
Only do this step if replacing the sensor.

(2) Install the clamping bushing into the knuckle

(Fig. 2) Only do this step if replacing the sensor
or the clamping bushing was damaged.

(3) Install the wheel speed sensor all the way into

the front wheel hub the wheel speed sensor will self
adjust when the vehicle is moved (Fig. 2).

(4) Install the front wheels.
(5) Lower the vehicle.

REAR WHEEL SPEED SENSOR

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Pull the wheel speed sensor out of the mount-

ing hole in the axle supporting tube (Fig. 3).

(4) Only do this step if sensor replacement is

necessary. Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 3).

(5) Remove clamping sleeve from the knuckle if

damaged or being replaced with new sensor (Fig.
3).

Fig. 1 Operation of the Wheel Speed Sensor

1 - MAGNETIC CORE
2 - CAB
3 - AIR GAP
4 - EXCITER RING
5 - COIL

Fig. 2 FRONT WHEEL SPEED SENSOR

1 - SHRINK-FIT SLEEVE
2 - CLAMPING BUSHING
3 - SPEED SENSOR
4 - SHRINK TUBE

BRAKES - ABS

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