2001 DODGE TOWN AND COUNTRY brake rotor

WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(4) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.).
(7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Remove brake pedal depressor tool.(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 75). It is a automatic-adjust-
ing type lever.
The vehicle has four flexible steel parking brake
cables. They are:
²Front
²Intermediate
²Left rear
²Right rear
The front parking brake cable extends from the
parking brake lever. A steel equalizer bracket con-
nects the front parking brake cable to the left rear
and intermediate cable. The intermediate cable is
connected to the right rear cable using a parking
brake cable connector.
On vehicles equipped with rear drum brakes, the
rear service brakes also act as the vehicle's parking
brakes.
Vehicles equipped with rear disc brakes use a
small duo-servo brake assembly mounted to the each
rear disc brake caliper adapter as the parking brake.
The inside of the brake rotor (hat section of drum-in-
Fig. 75 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5 - 50 BRAKES - BASERS
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hat style brake rotor) is used as the parking brake
drum.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment.
When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel.
The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park-
ing brake cables.
An equalizer bracket is used at the rear end of the
front parking brake cable to distribute tension
equally to each parking brake cable.
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RELEASE
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
This parking brake lever (pedal) mechanism is
designed so that the adjuster mechanism will rotate
only half a turn when the tension is released from
the parking brake cable. This eliminates the require-
ment to lock out the automatic adjuster when servic-
ing the parking brake lever (pedal) mechanism and
cables.
Use the following procedure to release the tension
from the parking brake cables and the automatic
adjuster in the parking brake lever (pedal) mecha-
nism.
(1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 76).
(2) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 77).
(3) Remove the equalizer from the front parking
brake cable.
(4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever (pedal) mechanism to rotate
around to its stop. This will remove the tension from
the adjuster and front park brake cable (Refer to 5 -BRAKES/PARKING BRAKE - STANDARD PROCE-
DURE).
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RESET
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
Fig. 76 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 77 Parking Brake Cable Attachment To
Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
RSBRAKES - BASE5-51
PARKING BRAKE (Continued)
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(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block.
(15) Remove park brake pedal release link from
park brake mechanism.
(16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
79).
(17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism.
(2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket.
(3) Install cable strand button into the clevis on
the park brake pedal mechanism.
(4) Install wiring harness connector on warning
indicator lamp ground switch.
(5) Install the park brake release rod on the
release mechanism of the park brake pedal.
(6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle.
(7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 79).
(8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 79).
(9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 79).
(10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.).
(11) Verify that the park brake pedal is in the fully
released (full up) position.
(12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 78).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer to 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism.
(16) Install the electrical junction block on the
instrument panel.
(17) Install the reinforcement on the lower instru-
ment panel.
(18) Install the steering column lower cover on the
lower instrument panel.(19) Install the silencer panel under the instru-
ment panel.
(20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door.
(22) Install the negative (ground) cable on the bat-
tery.
(23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) Set the parking brake.The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove the wheel and tire assembly.
(4) Remove the cotter pin and nut retainer (Fig.
80) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 81) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 82) from
the stub shaft of the outer C/V joint.
(7) Release the parking brake.
Fig. 80 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RSBRAKES - BASE5-53
LEVER (Continued)
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(8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 83).(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 84).
(10) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 85).
Fig. 81 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 82 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 83 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 84 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5 - 54 BRAKES - BASERS
SHOES (Continued)
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(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
86).
(12) Remove the rotor from the hub/bearing.
(13) Remove the horseshoe clip (Fig. 87) from the
retainer on the end of the park brake cable.
(14) Remove the end of the park brake cable from
the actuator lever on the adapter (Fig. 87).(15) Remove the end of the park brake cable from
the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in (Fig. 88) to compress
the locking tabs on the park brake cable retainer.
(16) Remove the attaching bolt from the wheel
speed sensor (Fig. 89). Then remove wheel speed sen-
sor from hub/bearing and adapter.
Fig. 85 Removing/Installing Caliper
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
Fig. 86 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 87 Park Brake Cable Attachment To Actuator
1 - ADAPTER
2 - PARK BRAKE CABLE
3 - ACTUATOR
4 - AXLE
5 - DRIVESHAFT
6 - PARK BRAKE CABLE RETAINER
7 - HORSESHOE CLIP
Fig. 88 Park Brake Cable Removal From Adapter
1 - DRIVESHAFT
2 - 1/2º WRENCH
3 - PARK BRAKE CABLE
4 - PARK BRAKE CABLE RETAINER
5 - ADAPTER
RSBRAKES - BASE5-55
SHOES (Continued)
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(12) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 89). Tighten the wheel speed sen-
sor attaching bolt to a torque of 12 N´m (105 in. lbs).
(13) Install the park brake cable into its mounting
hole in the adapter.Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter.
(14) Install the end of the park brake cable on the
park brake actuator lever (Fig. 87).
NOTE: The horseshoe clip must be installed and
installed properly when the park brake cable is
installed in the adapter. The purpose of the horse-
shoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not
installed the park brake cable retainer will rattle in
the adapter.
(15) Install aNEWhorseshoe clip on the park
brake cable retainer (Fig. 87). The horseshoe clip is
installed between the retainer for the park brake
cable and the adapter. Horseshoe clip must be
installed with the curved end of the clip pointing
straight up and the edge of the curved end facing
toward the rear of the vehicle (Fig. 87).
(16) Remove the locking pliers (Fig. 83) from the
front park brake cable.
(17) Adjust the park brake drum-in-hat brake
shoes. (Refer to 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS).
(18) Install the rotor on the hub/bearing.
(19) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 85).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(20) Install the caliper guide pin bolts (Fig. 84).
Tighten the guide pin bolts to a torque of 22 N´m
(192 in. lbs.).
(21) Clean all foreign material off the threads of
the outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 82) on the stub shaft of the outer C/V
joint.
(22) Set the parking brake.
(23) Tighten the hub nut to a torque of 244 N´m
(180 ft. lbs.).
(24) Install the spring washer (Fig. 81) on the stub
shaft of the outer C/V joint.
(25) Install the nut retainer and cotter pin (Fig.
80) on the stub shaft of the outer C/V joint.
(26) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequenceuntil all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(27) Lower vehicle.
(28) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(29) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 100). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
Fig. 100 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
RSBRAKES - BASE5-59
SHOES (Continued)
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NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Using Gauge, Brake Shoe, Special Tool C-3919
or an equivalent,accuratelymeasure the inside
diameter of the park brake drum portion of the rotor
(Fig. 101).
(6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 102).
(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 103).(8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes.
(9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Fig. 100). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
Fig. 101 Measuring Park Brake Drum Diameter
Fig. 102 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 103 Setting Gauge To Park Brake Shoe
Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
5 - 60 BRAKES - BASERS
SHOES (Continued)
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BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 10
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION............................1
HYDRAULIC/MECHANICAL
DESCRIPTION............................1
FLUID
STANDARD PROCEDURE...................1
BRAKE FLUID LEVEL CHECKING...........1
MASTER CYLINDER - RHD
DESCRIPTION............................2
REMOVAL...............................2
INSTALLATION............................3
PEDAL TORQUE SHAFT
REMOVAL...............................3
INSTALLATION............................4POWER BRAKE BOOSTER - RHD
REMOVAL...............................4
INSTALLATION............................6
ROTORS
SPECIFICATIONS.........................8
PARKING BRAKE
DESCRIPTION............................8
CABLES - PARKING BRAKE
REMOVAL...............................8
INSTALLATION............................8
LEVER - PARKING BRAKE
REMOVAL...............................8
INSTALLATION............................9
BRAKES - BASE
DESCRIPTION - BASE BRAKES
Four-Wheel Disc Antilock Brakes are standard on
all models.
HYDRAULIC/MECHANICAL
DESCRIPTION - DISC BRAKES
All vehicles are equipped with Four-Wheel-Disc
brakes. Both 15º (BRE) and 16º (BR3) disc/disc brake
systems are available. The disc brakes are manufac-
tured by Continental Teves. The BR3 system is stan-
dard equipment on all-wheel drive and all right-hand
drive models. It is optional on other models.
The BR3 system features larger, externally vented
front brake rotors.
Although there are different disc/disc systems, they
are serviced using the same service procedures. Some
specifications differ.
FLUID
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING
Right hand drive vehicles feature a brake fluid res-
ervoir with the same markings as left hand drive res-
ervoirs.
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Fluid reservoirs are marked with the words FULL
and ADD to indicate proper brake fluid fill level of
the master cylinder.
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.
Use only Mopartbrake fluid or equivalent from a
sealed container. Brake fluid must conform to DOT 3
specifications (DOT 4 or DOT 4+ are acceptable).
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
RGBRAKES5a-1
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