2002 CHRYSLER CARAVAN lock

RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated.6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage.2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK1. Broken or missing anti-rattle
spring clips on shoes.1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.1. Replace brake drums as necessary.
DRUM BRAKE HOWL OR
MOAN1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING1. ABS wheel speed sensor or tone
wheel.1. Inspect, correct or replace faulty
component(s).
RSBRAKES - BASE5-5
BRAKES - BASE (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)1. One of the two hydraulic circuits
to the front brakes is malfunctioning.1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles).2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist.3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N1. Brake lamp switch out of
adjustment.1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment.1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
RSBRAKES - BASE5-7
BRAKES - BASE (Continued)
ProCarManuals.com

(6) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
ABS ICU Mounting Bolts To
Bracket11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts28 21 250
ABS CAB-To-HCU Mounting
Screws2Ð17
ABS Wheel Speed Sensor
Head Mounting Bolt - Front13 Ð 115
ABS Wheel Speed Sensor
Head Mounting Bolt - Rear10 Ð 90
Adjustable Pedal Position
Sensor Mounting Screws7.5 66 Ð
Adjustable Pedal Module
Mounting Screws2.0 15 Ð
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt47 35 Ð
Disc Brake Caliper Guide
Pin Bolts35 26 Ð
Disc Brake Caliper Bleeder
Screw15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw10 Ð 80
Drum Brake Support Plate
Mounting Bolts130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts28 21 250
Master Cylinder Mounting
Nuts25 19 225
Power Brake Booster
Mounting Nuts28 21 250
Proportioning Valve
Mounting Bolts54 40 Ð
Proportioning Valve Axle
Bracket Mounting Bolt20 Ð 175
Parking Brake Lever (Pedal)
Mounting Bolts And Nut28 21 250
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
BASE BRAKE SYSTEM
Fig. 3 TOOL 6921 INSTALLED ON MASTER
CYLINDER
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
Tubes, Master Cylinder Bleeding 6920
RSBRAKES - BASE5-9
BRAKES - BASE (Continued)
ProCarManuals.com

BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 4).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:
²Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system.
²Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid.If
the brake fluid level has dropped below the add
line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 4).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch.
(3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.
(2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 4).
Tubes, Master Cylinder Bleed 8358
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Safe-Set
Handle, Universal C±4171
Installer, Dust Boot C-4689 or C-4842
5 - 10 BRAKES - BASERS
BRAKES - BASE (Continued)
ProCarManuals.com

ADJUSTABLE PEDAL SWITCH
DESCRIPTION
The adjustable pedal switch is mounted on the left
side of the lower steering column shroud (Fig. 5). The
adjustable pedal switch adjusts the adjustable pedal
assembly fore-and-aft. The pedal assembly moves in
the direction the switch is actuated.
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SWITCH
Refer to Appropriate Diagnostic Information.
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 6).
(4) Disconnect parking brake release link at
release handle.
(5) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.
(6) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 6).
(7) Remove screws fastening upper and lower
steering column shrouds to steering column (Fig. 7).
(8) Remove the lower shroud with adjustable pedal
switch; disconnect switch wiring connector along left
side of column as shroud is removed (Fig. 8).
Fig. 4 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 5 Adjustable Pedal Switch Location
1 - ADJUSTABLE PEDAL SWITCH
2 - LOWER STEERING COLUMN SHROUD
Fig. 6 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
RSBRAKES - BASE5-11
BRAKE FLUID LEVEL SWITCH (Continued)
ProCarManuals.com

(9) Depress retainers on rear of adjustable pedal
switch, then remove switch from lower shroud (Fig.
9).
INSTALLATION
(1) Guide adjustable pedal switch wiring through
mounting hole in lower shroud.
(2) Align switch retainers with notches in mount-
ing hole and snap the switch into place (Fig. 9).
(3) Connect adjustable pedal switch wiring connec-
tor along left side of column (Fig. 8).(4) Install the lower shroud with adjustable pedal
switch. Install screws fastening steering column
shrouds to steering column (Fig. 7).
(5) Install knee blocker reinforcement plate (Fig.
6).
(6) Connect parking brake release link to release
handle.
(7) Install data link diagnostic connector to mount-
ing hole in reinforcement plate.
(8) Install lower steering column cover/knee
blocker (Fig. 6).
(9) Install silencer panel below lower steering col-
umn cover/knee blocker.
(10) Connect ground cable to negative post of bat-
tery.
(11) Connect scan tool (DRBIIIt) to data link diag-
nostic connector located below steering column.
(12) Turn ignition key to ON position.
(13) Using scan tool, check for and clear any exist-
ing adjustable pedal fault codes.
(14) Test operation of adjustable pedals, memory
sets and RKE (if equipped). If applicable, reset radio
and clock.
(15) Recheck for any fault codes.
(16) Turn key to OFF and remove scan tool from
vehicle.
PEDAL POSITION SENSOR
DESCRIPTION
The pedal position sensor is part of the adjustable
pedal assembly. It is mounted to the left of the brake
pedal (Fig. 10). It senses the fore and aft position of
the brake pedal.
Fig. 7 Steering Column Shrouds
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 8 Pedal Switch Wiring Connector
1 - STEERING COLUMN FIXED SHROUD
2 - BRAKE TRANSMISSION SHIFT INTERLOCK
3 - B.T.S.I. WIRING CONNECTOR
4 - PEDAL SWITCH WIRING CONNECTOR
Fig. 9 Pedal Switch Retainers
1 - LOWER SHROUD INTERIOR
2 - RETAINERS
5 - 12 BRAKES - BASERS
ADJUSTABLE PEDAL SWITCH (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING - PEDAL POSITION
SENSOR
Refer to Appropriate Diagnostic Information.
REMOVAL
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Press release tab to the left (Fig. 11), then
remove bulkhead connector from bracket by pulling it
toward lower steering column cover.(4) Move bulkhead connector toward left side of
vehicle as far as its wires will allow. Do not over-
stress wiring.
(5) Remove two mounting screws securing pedal
position sensor in place (Fig. 12).
(6) Remove pedal position sensor from bracket.
(7) Disconnect wiring connector and remove pedal
position sensor.
INSTALLATION
(1) Connect wiring connector to pedal position sen-
sor.
NOTE: Make sure pin in pedal assembly fits into
slot in sensor carriage when installing sensor.
(2) Place sensor against mounting bracket and into
brake pedal (Fig. 12). Move carriage as necessary to
align slot with pin. Install two mounting screws.
Tighten screws to 7.5 N´m (66 in. lbs.) torque.
(3) Align the bulkhead connector mounting slot
with its bracket and install it, locking it in place.
(4) Install silencer panel below lower steering col-
umn cover.
(5) Connect ground cable to negative post of bat-
tery.
(6) Connect scan tool (DRBIIIt) to data link diag-
nostic connector located below steering column.
(7) Turn ignition key to ON position.
(8) Using scan tool, check for and clear any exist-
ing adjustable pedal fault codes.
(9) Test operation of adjustable pedals, memory
sets (if equipped), and RKE (if equipped). If applica-
ble, reset radio and clock.
(10) Recheck for any fault codes.
Fig. 10 Pedal Position Sensor Location
1 - PEDAL POSITION SENSOR
2 - BRAKE PEDAL
Fig. 11 Bulkhead Connector Release Tab
1 - RELEASE TAB
2 - PEDAL POSITION SENSOR
3 - BULKHEAD CONNECTOR
Fig. 12 Pedal Position Sensor
1 - WIRING CONNECTOR
2 - GEAR BOX
3 - PEDAL POSITION SENSOR
RSBRAKES - BASE5-13
PEDAL POSITION SENSOR (Continued)
ProCarManuals.com

BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
The brake tubes are steel with a corrosion-resis-
tant nylon coating applied to the external surfaces.
The flex hoses are made of reinforced rubber with fit-
tings at each end.
The primary and secondary brake tubes leading
from the master cylinder to the ABS ICU Hydraulic
Control Unit (HCU) or the non-ABS junction block
have a special flexible section. This flexible section is
required due to cradle movement while the vehicle is
in motion (The ICU and non-ABS junction block are
mounted to the cradle).If replacement of these
lines is necessary, only the original factory
brake line containing the flexible section must
be used.
OPERATION - BRAKE TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle's suspension.
INSPECTION - BRAKE TUBES AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference.
The brake tubing should be inspected periodically
for evidence of physical damage or contact with mov-
ing or hot components.
The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections must also be inspected. This flexible tub-
ing must be inspected for kinks, fraying and contact
with other components or with the body of the vehi-
cle.
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove both front wheel and tire assemblies.
(3) Begin on one side of the vehicle.
(4) Remove the anti-rattle clip from the outboard
side of the caliper and adapter.
(5) Remove the two caliper guide pin bolts.
(6) Remove caliper from caliper adapter and brake
rotor.
CAUTION: Supporting weight of caliper by the flex-
ible brake fluid hose can damage the hose.
(7) Using wire or cord, hang the caliper from the
front strut assembly (Fig. 20). Support the caliper
firmly to prevent weight of caliper from being sup-
ported by the brake fluid hose.
(8) Remove the outboard brake shoe from the cali-
per adapter.
(9) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip on shoe is free
from the cavity in the caliper piston (Fig. 21).
(10) Repeat the above procedure on other side of
the vehicle.
Fig. 20 Stored Front Disc Brake Caliper
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
RSBRAKES - BASE5-17
ProCarManuals.com