Dodge Viper SRT-10 (ZB). Manual - part 39

Machine both sides of the brake rotor at the same

time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut. For brake
rotor specifications, (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/ROTOR - SPECIFICATIONS).

REMOVAL

REMOVAL - BRAKE ROTOR (FRONT)

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

(1) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove wheel and tire assembly from vehicle.

(Refer to 22 - TIRES/WHEELS - REMOVAL)

(3) Remove two bolts attaching brake caliper to

steering knuckle (Fig. 55).

CAUTION: When remotely hanging brake caliper, do
not allow caliper to hang by brake hose. Damage to
the hose can occur.

(4) Remove brake caliper from steering knuckle.

Support brake caliper by hanging it from upper con-
trol arm using mechanics wire.

NOTE: If the same rotor is to be installed, before
removal, place a chalk mark on a wheel mounting
stud and on the rotor near that stud. That way, the
rotor can be reinstalled in the same location utiliz-
ing those marks.

(5) Remove brake rotor from hub and bearing

assembly (Fig. 55).

REMOVAL - BRAKE ROTOR (REAR)

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

(1) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

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

TIRES/WHEELS - REMOVAL)

(3) Remove two bolts attaching parking brake cal-

iper to knuckle (Fig. 56).

(4) Remove parking brake caliper from knuckle.

Support brake caliper by hanging it from upper con-
trol arm using mechanics wire.

(5) Remove two bolts attaching hydraulic brake

caliper to knuckle (Fig. 57).

(6) Remove hydraulic brake caliper from knuckle.

Support brake caliper by hanging it from upper con-
trol arm using mechanics wire.

Fig. 54 Minimum Brake Rotor Thickness Markings

(Typical)

1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR

Fig. 55 Front Brake Caliper And Rotor Mounting

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

5 - 34

BRAKES - BASE

ROTOR (Continued)

(7) Remove brake rotor from vehicle. (Fig. 57)

INSTALLATION

INSTALLATION - BRAKE ROTOR (FRONT)

(1) Install brake rotor on hub and bearing assem-

bly. (Fig. 55)

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

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

(3) 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.

(4) Lower vehicle.

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

(5) Pump brake pedal several times, then adjust

brake fluid level as necessary.

(6) 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).

INSTALLATION - BRAKE ROTOR (REAR)

(1) Install brake rotor on hub wheel mounting

studs (Fig. 57). If same rotor is being reinstalled,
remember to align marked rotor hole with marked
wheel mounting stud.

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

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

(3) To reinstall parking brake caliper, it may be

necessary to seat piston in its bore. Seat piston in its
bore as follows:

(a) Using a pin punch, tap parking brake shoe

retaining pin out of caliper.

(b) Remove anti-rattle spring and parking brake

shoes.

Special Tool 6366, into holes in top of piston.

(d) Rotate Piston Retractor clockwise until pis-

ton is fully seated (bottomed) in its bore. Remove
tool.

(e) Install

parking

brake

shoes

caliper

(Inboard and outboard shoes are identical).

(f) Position anti-rattle spring and slide retaining

pin through anti-rattle spring and shoes.

(g) Using a pin punch, continue to install retain-

ing pin into caliper until snap ring on end of
retaining pin is fully seated in outboard side of cal-
iper.

Fig. 56 Parking Brake Caliper Mounting

1 - KNUCKLE
2 - ROTOR
3 - PARKING BRAKE CALIPER
4 - LOWER MOUNTING BOLT
5 - UPPER MOUNTING BOLT

Fig. 57 Rear Brake Caliper And Rotor Mounting

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

BRAKES - BASE

5 - 35

ROTOR (Continued)

(4) Install parking brake caliper on knuckle (Fig.

56). Install brake caliper mounting bolts. Tighten
upper mounting bolt to 32 N·m (24 ft. lbs.) torque.
Tighten lower mounting bolt to 52 N·m (38 ft. lbs.)
torque.

(5) 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.

(6) Lower vehicle.
(7) Cycle parking brake several times to adjust.

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

(8) Pump brake pedal several times, then adjust

brake fluid level as necessary.

(9) 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).

SPECIFICATIONS

BRAKE ROTOR LIMITS/SPECIFICATIONS

When refacing a rotor, the required TIR (Total

Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.

NOTE: Although front and rear rotor specifications
are the same in the following table, front and rear
rotors are not interchangeable. Front rotors have a
different offset than do rears.

Brake

Rotor

Rotor Thickness

Minimum Rotor

Thickness

Rotor Thick-

ness Variation

Rotor Runout*

Rotor Micro

Finish

Front

32.10-31.90 mm

1.264-1.256 in.

30.0 mm

1.181 in.

0.010 mm

0.0004 in.

0.030 mm

0.001 in.

15-80 RMS

Rear

32.10-31.90 mm

1.264-1.256 in.

30.0 mm

1.181 in.

0.010 mm

0.0004 in.

0.030 mm

0.001 in.

15-80 RMS

* TIR Total Indicator Reading (Measured On Vehicle)

PARKING BRAKE

DESCRIPTION

The parking brake lever mounts to the floor pan

tunnel beneath the center console. It has a short out-
put cable and equalizer bracket attached to it. Two
parking brake cables attach to the equalizer bracket.
These cables lead to the operating lever of the park-
ing brake caliper at each rear brake rotor. The park-
ing brake lever is spring loaded allowing the parking
brake to be self-adjusting.

The complete parking brake mechanism inside

each parking brake caliper consists of:

• a piston

• a worm shaft

• two discs (drive and driven)

• a disc preload spring

• an operating lever, and

• a return spring

OPERATION

When the parking brake is applied, the parking

brake cables pull on the operating levers of the park-
ing brake calipers. This rotates the discs and worm
shaft inside each caliper causing the piston to extend
and apply the brakes. Since normal brake shoe oper-
ating clearance is quite small, only a modest amount
of piston movement is needed for brake application.
A stop bolt is used to limit the total amount of piston
extension.

The worm shaft is attached to the piston with a

spring washer and lock ring. The driven disc is
threaded to the worm shaft and the drive disc is
seated in the caliper. The operating lever is bolted to
the drive disc. The operating lever is connected to
and operated by the parking brake rear cable. The
lever return spring is attached to the operating lever
and a bracket on the caliper body.

The drive disc rotates the spring loaded driven disc

by means of ball bearings. The bearings are secured
to the drive disc and seat in cam ramps machined in
the driven disc.

5 - 36

BRAKES - BASE

ROTOR (Continued)

The parking brake mechanism is self-adjusting to

compensate for lining wear. As wear occurs, drive-to-
driven disc clearance increases. This causes the drive
disc ball bearings to move farther up the cam ramps
in the driven disc increasing the amount of rotation.
The extra rotation produced is enough to extend the
piston for adjustment.

STANDARD PROCEDURE

STANDARD PROCEDURE - AUTOMATIC
ADJUSTER LOCKING OUT

(1) Disconnect negative (-) cable from negative ter-

minal on battery. Be sure battery cable is isolated
from battery.

(2) Block tire and wheel assemblies so vehicle does

not move once vehicle parking brake is released.

(3) Fully apply parking brake lever.
(4) Remove center console. (Refer to 23 - BODY/

INTERIOR/CENTER CONSOLE - REMOVAL)

(5) Lower parking brake lever handle to released

position.

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCKSPRING LOADED TO APPROXIMATELY 19
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE PARK-
ING BRAKE CABLES AND EQUALIZER ARE CON-
NECTED TO THE LEVER OUTPUT CABLE. KEEP
HANDS OUT OF AUTOMATIC ADJUSTER SECTOR
AND PAWL AREA. FAILURE TO OBSERVE CAUTION
IN HANDLING THIS MECHANISM COULD LEAD TO
SERIOUS INJURY.

(6) Grasp parking brake lever output cable by

hand and pull upward. Continue pulling on cable
until a screwdriver (pin punch or appropriate pin)
can be inserted through hole in left side of lever
mechanism, behind sector gear and out hole in right
side of lever (Fig. 58). This will lock parking brake
automatic adjustment mechanism in place and take
tension off parking brake cables.

STANDARD PROCEDURE - AUTOMATIC
ADJUSTER UNLOCKING

(1) Make sure parking brake cables are both prop-

erly installed in equalizer.

(2) Keeping hands clear of automatic adjuster sec-

tor and pawl area, firmly grasp screwdriver (pin
punch or locking pin if a new lever has been
installed) installed in lever mechanism (Fig. 58), then
quickly remove it from parking brake lever mecha-
nism. This action allows parking brake lever mecha-
nism to automatically take up any slack.

(3) Cycle parking brake lever once to position

parking brake cables, then return lever its released
position.

(4) Raise vehicle far enough for rear wheels to

clear floor. (Refer to LUBRICATION & MAINTE-
NANCE/HOISTING - STANDARD PROCEDURE)

(5) Check rear wheels of vehicle. They should

rotate freely without dragging with lever in released
position.

(6) Lower vehicle.
(7) Fully apply parking brake lever.
(8) Install center console. (Refer to 23 - BODY/IN-

TERIOR/CENTER CONSOLE - INSTALLATION)

(9) Connect negative (-) battery cable to negative

battery post.

(10) Remove blocks from tire and wheel assem-

blies.

CABLE - PARKING BRAKE

REMOVAL

NOTE: Before proceeding, review Warnings and
Cautions (Refer to 5 - BRAKES - WARNING).

Procedure below applies to either rear parking

brake cable. Right cable is shown; left cable is typi-
cal.

(1) Block tire and wheel assemblies so vehicle does

not move once vehicle parking brake lever released.

(2) Fully apply parking brake lever.
(3) Remove center console. (Refer to 23 - BODY/

INTERIOR/CENTER CONSOLE - REMOVAL)

BRAKES - BASE

5 - 37

PARKING BRAKE (Continued)

Content .. 37 38 39 40 ..