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Can’t Dodge® this Durango® Pulsation
Eric Seifert, Automotive Technical Editor

Paul likes jammin’ to all the latest tunes in his 2004 Dodge Durango. His mobile DJ business makes good use of the Durango’s room to transport equipment from gig to gig. On his way home from a wedding reception Sunday, Paul noticed a different kind of pulsation in the Durango. It only would occur when he lightly applied the brakes over 60 mph. I booked Paul for a gig in my shop on Tuesday.

The vehicle may exhibit pulsation or vibration in the brake pedal and/or steering wheel when the brakes are applied. The condition is most noticeable at speed over 50 MPH but can occur at lower speeds. If the customer indicates that the condition is present, perform the Repair Procedure. The procedure involves installing brake pads, resurfacing the rotors and checking rotor runout.

1 Set of Brake Pads, P/N 05139733AA, will be required to complete the repair.
Applicable Vehicles: 2004-2005 Durango (HB)

Repair Procedure:
(Review safety procedures in the® before beginning)

1. Inspect the front brakes for any signs of abnormal wear or damage. Repair as necessary.Dodge Rotor Resurface Specs

2. Resurface the front brake rotors with a Chrysler® approved on-car brake lathe. If an on-car lathe is not available, the rotor resurfacing must be sublet to a facility with an approved on-car lathe.

3. Remove the calipers.

4. Clean the caliper adapter.

5. Replace the front pads and anti-rattle springs with P/N 05139133AA.

6. Mark one wheel stud on each side with a dab of paint or suitable marker.
NOTE: Wheel stud torque is critical to the success of the repair. The following procedure is intended to identify excessive rotor distortion which could be caused by improper wheel stud torque.

Dial Indicator7. Install the wheel and assembly to the hub. Pre-tighten the lug nuts in a cross pattern to 100 Nm (75 ft.lbs.) then final tighten the lug nuts in a cross pattern to:
200 Nm (145 ft.lbs.) for steel wheels or 175 Nm (130 ft.lbs.) for aluminum wheels. Mark the wheel at the same location as the marked wheel stud.

8. Set up a dial indicator to measure mounted rotor runout. Place the dial indicator plunger against the inner machined rotor face, visible between the brake caliper and the front splash shield (Fig. 1). Rotate the wheel and tire assembly two turns and take runout measurement. If the measurement is less than .025 mm (.001 in.) no further action is required. If the measurement is greater than .025 mm (.001 in.) remove the lug nuts and relocate the wheel one stud clockwise, tighten the lug nuts as described in step 7 and check the runout again. Do not remove any brake parts. Repeat step 8 for each wheel location until you achieve the lowest mounted runout. Minimum mounted rotor runout will be achieved by moving the wheel, not the rotor.

Written by ALLDATA Technical Editor, Eric Seifert. Eric is an ASE certified Master Technician and Engine Machinist. He is a graduate of the De Anza College Automotive Technology Program, with 20 years of independent shop and parts store experience.

©ALLDATA LLC. All rights reserved. All technical information, images and specifications are from ALLDATA Repair. ALLDATA is a registered trademark and ALLDATA Repair is a mark of ALLDATA LLC. All other marks are the property of their respective holders.

Durango, Dodge and Chrysler are registered trademark names and model designations of Chrysler LLC. All trademark names and model designations are being used solely for reference and application purposes.

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