ANY time a caliper slides, which obviously is what they do, there is a risk of binding especially in the case of worn or rusted bolts. I've seen it happen on lighter vehicles. Notice I said bolts, not pins. I'm reasonably sure you know that many other vehicles use the concept of a long carriage bolt (not threaded along the entire shaft) rather than a tapered/threaded pin such as what we find on the Durango. In my opinion, it's a lousy and horrible design. There is no need to taper a pin like that, compromising the integrity of it's ability adequately tighten to the knuckle without risk. Just not very smart when you step away from an industry standard.

 

NO: 05-06-98

SUBJECT: Rattle Noise Coming From Front Brake Caliper Area

DATE: Oct. 9, 1998

SYMPTOM/CONDITION:

Rattle noise coming from the front brake caliper area while driving on a rough surfaced road that disappears when the brakes are applied.

DIAGNOSIS:

While driving the vehicle on a rough surfaced road, listen for a rattling noise coming from the front brake caliper area. If a rattling noise is heard, lightly apply the brakes. If the noise disappears, perform the following Repair Procedure.

PARTS REQUIRED:


Qty Part No. Description
1 05014095AB Kit, Front Brake Shoe
AR (1) 52039450AB Knuckle, Right Side Steering
AR (1) 52039451AB Knuckle, Left Side Steering
AR (1) 04318080 Fluid, Mopar Brake

REPAIR PROCEDURE:

This bulletin involves installing a revised set of front brake shoes.
1.Clean master cylinder reservoir and filler caps.
2.Remove the reservoir filler cap and drain approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to drain the brake fluid.
3.Raise and support the vehicle.
4.Remove front wheel and tire assemblies.
1.Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe.
5.Remove the caliper slide pins.
6.Remove caliper from caliper adapter.

CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TOSUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES.
7.Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper.
8.Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2).
9.Inspect the caliper adapter for wear in the location where the brake shoes rest on the adapter (Figure 3). If the wear is greater than 1.5 mm (0.060 in.) from the original surface, replace the steering knuckle (see Parts Required section). Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 2-7 and 2-8 for information regarding steering knuckle service. If the brake caliper adapter does not show signs of wear, clean the slide surfaces of the brake caliper adapter ledges with a wire brush.
10.Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston.
11.Insert outboard brake shoe into the caliper (Figure 4).
12.Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 5).
13.Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges.
14.Install and tighten the caliper slide pins to 25 - 35 N•m (18 - 26 ft. lbs.).

NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS.
15.Perform Step 5 through Step 16 to the front brakes on the other side of the vehicle.
16.Install the wheel and tire assemblies.
17.Remove supports and lower the vehicle.
18.Pump the brake pedal several times to seat the new brake shoes.

CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE.
19.Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080.
20.Drive the vehicle again on a rough surfaced road and make a few light to moderate brake applications to ensure that the rattle noise has been eliminated.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:


Labor Op. No. Description Time
05-70-22-93 Replace Front Brake Shoes 0.6 Hrs.

Relate Operation No:


Labor Op. No. Description Time
02-05-31-50 Replace Steering Knuckle, Right Side 0.9 Hrs.
02-05-31-51 Replace Steering Knuckle, Left Side 0.9 Hrs.

FAILURE CODE:


Code Description
P8 New Part

 

Thanks Master Tech for the info, but I'm not getting any kind of a rattle. I'm getting a clunk and it happens even if the truck is barely even moving and I apply the brake or upon initial acceleration from a dead stop.

 

Check to make sure your wheel nuts are tight, it sounds like your brake discs might be hitting the studs making that noise.

 

Okay, I have a few more TSB's.

NO: 02-05-99

SUBJECT: Squeak Or Creak From Front Wheel Area At Low Speeds.

DATE: June 11, 1999

OVERVIEW:

This bulletin involves installing a new hub/bearing assembly.

NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES.

SYMPTOM/CONDITION:

A squeak or creak can be heard coming from the front wheel area while driving slowly and brakes not applied. In some cases, a slight brake pedal pulsation might be felt.

DIAGNOSIS:
1.Raise the vehicle on a hoist.
2.Remove both front wheel/tire assemblies.
3.Remove the spindle nut cotter pin and washer.
4.Check the spindle nut retaining torque. The nut should be tightened to 271 N• m (200 ft. lbs.).

NOTE: IF THE NUT IS TORQUED TO LESS THAN 54 N• m (40 ft. lbs.), PERFORM THE REPAIR PROCEDURE.
5.Inspect the steering knuckle brake caliper/pad support rail for wear in the location where the brake shoes rest on the rail (Figure 1). If the wear is greater than 1.5 mm (0.060 in.) deep from the original surface, the steering knuckle must be replaced. Refer to the 1999 Dakota Service Manual (Publication No. 81-370-9110), pages 2-8 or 2-16 and 2-17 for information regarding steering knuckle service.
6.Clean master cylinder reservoir and filler caps.
7.Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use a clean suction gun or similar device to remove the brake fluid.
8.Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe.
9.Remove the caliper slide pins.
10.Remove caliper from steering knuckle.

CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER.
11.Secure a dial indicator to the steering knuckle. Position the tip of the dial indicator onto the hub/bearing assembly wheel-mounting surface just outside of the wheel stud circumference (Figure 2).
12.Zero the dial indicator. Then, slowly rotate the hub/bearing assembly while recording the runnout measurement.
13.If the runnout measurement exceeds 0.1 mm (0.004 in.), perform the following Repair Procedure. If the runnout measurement is less than 0.1 mm (0.004 in.), further diagnosis is required. Refer to the appropriate Service Manual, Groups 02, 05, and 22 for information regarding front suspension, brakes, or tire/wheel diagnosis.

NOTE: THE DIAGNOSIS SHOULD BE PERFORMED TO BOTH RIGHT AND LEFT SIDES OF THE VEHICLE. ONLY PERFORM THE REPAIR PROCEDURE TO HUB/BEARING ASSEMBLIES THAT EXCEED 0.1 MM (0.004 IN.) RUNNOUT.

PARTS REQUIRED:


Qty Part No. Description
AR (2) 52009528 Assembly, Hub/Bearing, Vehicles Equipped With Rear Wheel Anitlock Brakes
AR (2) 52009406 Assembly, Hub/Bearing, Vehicles Equipped With Four Wheel Antilock Brakes
AR (2) 06504007 Nut, Spindle


EQUIPMENT REQUIRED:


Dial Indicator With Clamping Base

REPAIR PROCEDURE:
1.Remove the hub bearing assembly and install a new hub/bearing assembly (see Parts Required section) and spindle nut p/n 06504007. Refer to the 1999 Dakota Service Manual (Publication No. 81-370-9110), page 2-11 or 2-20 and 2-21 for information regarding hub/bearing removal and installation procedures.

NOTE: PERFORM THE REPAIR PROCEDURE TO ANY HUB/BEARING ASSEMBLY THAT EXCEEDS 0.1 MM (0.004 IN.) RUNNOUT.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:


Labor Op. No. Description Time
22-45-02-96 Remove And Install Hub/Bearing Assembly One Side 0.9 Hrs.
22-45-02-97 Remove And Install Hub/Bearing Assembly Both Sides 1.1 Hrs.

FAILURE CODE:


Code Description
P8 New Part

NO: 05-03-99

SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair

DATE: Apr. 23, 1999

OVERVIEW:

This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location.

DISCUSSION:

A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit.

DIAGNOSIS:
1.Place the vehicle on an appropriate hoist.
2.Remove the front tire/wheel assembly.
3.Remove the brake caliper housing assembly by loosening the mounting bolts.

NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED.
4.Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger.

NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT.
5.If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor.
6.Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure.

PARTS REQUIRED:

Qty Part No. Description
AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes:
23/64 Drill Bit
M9 X 1.25 Tap
Heli-Coil Installation Tool
Heli-Coil Tang Break-Off Rod
(25) M9 X 1.25 Stainless Steel Heli-Coils

REPAIR PROCEDURE:
1.Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drillperpendicular to the knuckle.
2.Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through.
3.Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool.
4.Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface.
5.Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer.
6.If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor.
7.Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N• m (22-26 ft. lbs.).
8.Install the tire/wheel assembly.
9.Lower the vehicle.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:


Labor Op. No. Description Time
05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs.
05-80-20-93 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs.

FAILURE CODE:


Code Description
XX Service Adjustment

NO: 05-05-98

SUBJECT: Brake Grind Or GrowlSound

DATE: Oct. 9,1998

SYMPTOM/CONDITION:

Brake grind or growl sound coming from the front brakes during low speed braking (less than five mph {eight kph}). These sounds will usually be heard during light to moderate brake applications and from speeds from zero to five (5) miles per hour (8 kph). During braking, these sounds will be characterized by:
•Growl/grind noise that may be accompanied by squeal
•Low frequency grinding noise that may be accompanied by pedal pulsation
•Steering wheel and seat vibration (in extreme conditions)

NOTE: NO REDUCTION IN BRAKING ABILITY OR PARTICULAR DAMAGE TO THE BRAKE SYSTEM WILL RESULT FROM THESE NOISES.

DIAGNOSIS:
1.Drive the vehicle on a smooth surfaced road in an area away from heavy traffic and high surrounding noise.
2.Make several stops from a moderate speed to generate some heat within the brake system.
3.Accelerate to 15 - 20 mph (24 - 32 kph), then apply moderate pressure to the brake pedal until the vehicle comes to a stop.
4.If a grinding/growling noise is coming from the front brakes, perform the Repair Procedure. If there is no noise, drive the vehicle for several miles (kilometers) with minimal brake applications to allow the brake system to cool or park the vehicle until the brakes cool, then repeat Steps 2 and 3 again. If the grinding/growling noise is now coming from the front brakes, perform the Repair Procedure.

PARTS REQUIRED:


Qty Part No. Description
1 05014095AB Kit, Front Brake Shoe
AR (2) 52009208 Rotor, Brake

REPAIR PROCEDURE:

This bulletin involves installing a revised set of front brake shoes.
1.Clean master cylinder reservoir and filler caps.
2.Remove the reservoir filler cap and remove approximately 1/4 of the fluid from the reservoir. Use aclean suction gun or similar device to drain the brake fluid.
3.Raise and support the vehicle.
4.Remove front wheel and tire assemblies.
1.Bottom the caliper pistons in the caliper bores using a large C-clamp. Position the C-clamp frame on the rear of the caliper and clamp screw on the outboard brake shoe.
5.Remove the caliper slide pins.
6.Remove caliper from caliper adapter.

CAUTION: DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE HOSE. USE A HANGER TO SUPPORT THE CALIPER WHILE SERVICING THE BRAKE SHOES.
7.Remove the outboard brake shoe (Figure 1). Pry one end of the shoe retainer spring away from the caliper, then tilt the shoe upward and rotate it out of the caliper.
8.Remove the inboard brake shoe by tilting the shoe outward until the retainer spring is clear of the caliper piston (Figure 2).
9.Remove any dirt or foreign material from the wear surface of the rotor.
10.Secure a dial indicator onto the steering knuckle so that the plunger of the dial indicator is positioned approximately 25.4 mm (1 in.) inward from the rotor’s edge (Figure 3). If the runout exceeds 0.102 mm (0.004 in.), replace the rotor with p/n 52009208 . Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement.
11.Position a micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference (Figure 4) and measure the rotor thickness. Take an additional 6 - 12 measurements around the rotor. If the thickness of the rotor varies more than 0.013 mm (0.0005 in.) from point to point, replace the rotor with p/n 52009208. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 5-16 for information regarding rotor replacement.
12.Install inboard brake shoe from brake shoe kit p/n 05014095AB. Be sure the retainer spring is firmly seated in the caliper piston.
13.Insert outboard brake shoe into the caliper (Figure 5).
14.Ensure the outboard brake shoe retainer springs are seated in the caliper (Figure 6).
15.Install caliper and brake shoe assembly over the rotor and into the adapter. Be sure the brake shoe tangs are properly seated on the adapter ledges.
16.Install and tighten the caliper slide pins to 25 - 35 N•m (18 - 26 ft. lbs.).

NOTE: START THE SLIDE PINS BY HAND BEFORE TIGHTENING. DO NOT CROSS THREAD THE PINS.
17.Perform Step 5 through Step 17 to the front brakes on the other side of the vehicle.
18.Install the wheel and tire assembly.
19.Remove supports and lower the vehicle.
20.Pump the brake pedal several times to seat the new brake shoes.

CAUTION: VERIFY A FIRM BRAKE PEDAL BEFORE MOVING THE VEHICLE.
21.Ensure that the master cylinder reservoir is at the proper level as indicated on the side of the reservoir. Fill the reservoir with Mopar Brake Fluid p/n 04318080.
22.Repeat the Diagnosis to ensure that the brake growl/grind noise has been eliminated.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:


Labor Op. No. Description Time
05-70-22-92 Replace Front Disc Brake Shoes 0.8 Hrs.

Relate Operation No:


Labor Op. No. Description Time
05-21-10-50 Replace Disc Brake Rotor, Right Side 0.1 Hrs.
05-21-10-51 Replace Disc Brake Rotor, Left Side 0.1 Hrs.


FAILURE CODE:



Code Description
P8 New Part

These should have your head spinning. LOL

 

One more information I almost forgot. Does the front brake pads have a caliper retention spring hold the caliper to the knuckle. If they are missing the Mopar number is 52010170AB X2 . One for each side