2003 CHRYSLER CARAVAN Service Manual

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Page 145 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
(1) Install output flange seal to differential hous-
ing using tool C4171A and 8493 (Fig. 57).
Fig. 54 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 55 Output Flange Removal
1 - WOOD B

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CHRYSLER CARAVAN 2003 Service Manual (2) Install ouput flange to differential assembly.
Verify that it is seated all the way into position by
attempting to pull out by hand.
(3) Install rear halfshaft inner joint to output
flange.
(4) In

Page 147 of 2177

CHRYSLER CARAVAN 2003 Service Manual ProCarManuals.com

Page 148 of 2177

CHRYSLER CARAVAN 2003 Service Manual BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 75
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 75
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES..............3
WARNING.............................4
CAUTION..............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................4
STANDARD PROCEDURE - BASE BRAKE
BLEEDING............................7
SPECIFICATIONS
BRAKE FASTENER TORQUE.............9
SPECIAL TOOLS
BASE BRAKE SYSTEM.................10
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................11
INSTALLATION.........................11
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 11
DESCRIPTION - DISC BRAKES (REAR)....12
DESCRIPTION - DISC BRAKES (EXPORT) . . 13
DESCRIPTION - DRUM BRAKES (REAR) . . . 13
OPERATION
OPERATION - DISC BRAKES (FRONT).....13
OPERATION - DISC BRAKES (REAR)......13
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................13
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES . 14
OPERATION - BRAKE TUBES AND HOSES . . . 14
INSPECTION - BRAKE TUBES AND HOSES . . . 14BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)..................14
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES).................15
CLEANING - DISC BRAKE SHOES..........16
INSPECTION - DISC BRAKE SHOES........16
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DISC BRAKES)............16
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DRUM BRAKES)...........17
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....17
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION - REAR DISC BRAKE SHOES . . 19
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....19
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................22
INSTALLATION - REAR DRUM BRAKE SHOES . 22
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................23
DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)..................24
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES).................24
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........24
DISASSEMBLY - CALIPER PISTON AND
SEAL...............................24
RSBRAKES5-1
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CHRYSLER CARAVAN 2003 Service Manual CLEANING - CALIPER...................25
INSPECTION - CALIPER..................25
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........25
ASSEMBLY - CALIPER PISTON AND SEAL . . 26

CLEANING - CALIPER...................25
INSPECTION - CALIPER..................25
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........25
ASSEMBLY - CALIPER PISTON AND SEAL . . 26
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DISC BRAKES)...........27
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DRUM BRAKES)..........27
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....27
DISASSEMBLY - CALIPER PISTON AND SEAL . 28
CLEANING - CALIPER...................29
INSPECTION - CALIPER..................29
ASSEMBLY - CALIPER PISTON AND SEAL . . . 29
INSTALLATION - REAR DISC BRAKE CALIPER . 30
DISC BRAKE CALIPER ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER...........................31
INSTALLATION - FRONT DISC BRAKE
CALIPER ADAPTER....................31
DISC BRAKE CALIPER GUIDE PINS
REMOVAL - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES).............31
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (DISC/DRUM BRAKES).......31
DRUM
REMOVAL.............................32
INSTALLATION.........................32
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................32
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................32
SPECIFICATIONS
BRAKE FLUID........................33
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK . 33
OPERATION - NON-ABS JUNCTION BLOCK . . 33
REMOVAL - NON-ABS JUNCTION BLOCK....33
INSTALLATION - NON-ABS JUNCTION BLOCK . 33
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................34
DESCRIPTION - RHD..................35
OPERATION...........................35
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................35
REMOVAL
REMOVAL - LHD......................36
REMOVAL - RHD......................37
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................37
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................38INSTALLATION
INSTALLATION - LHD..................38
INSTALLATION - RHD..................39
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................39
INSTALLATION.........................39
POWER BRAKE BOOSTER
DESCRIPTION.........................40
OPERATION...........................41
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................41
REMOVAL
REMOVAL - LHD......................42
REMOVAL - RHD......................43
INSTALLATION
INSTALLATION - LHD..................46
INSTALLATION - RHD..................47
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................48
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................48
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................49
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................50
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................51
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 51
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................53
REMOVAL - FRONT BRAKE ROTOR........54
INSTALLATION - FRONT BRAKE ROTOR.....54
SPECIFICATIONS
BRAKE ROTOR.......................55
BRAKE ROTOR - EXPORT..............55
SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................56
INSTALLATION.........................56
WHEEL CYLINDERS
REMOVAL.............................57
INSPECTION..........................57
INSTALLATION.........................57
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................57
DESCRIPTION - EXPORT...............58
OPERATION...........................58
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................58
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................59
5 - 2 BRAKES - BASERS
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Page 150 of 2177

CHRYSLER CARAVAN 2003 Service Manual CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE
(FRONT)............................59
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)......................60
REMOVAL - PARKING BRAKE CABLE
(R

CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE
(FRONT)............................59
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)......................60
REMOVAL - PARKING BRAKE CABLE
(RIGHT REAR)........................60
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)..............................62
INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)............................63
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)......................63
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)........................63
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR).........................64ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 64
CABLES - PARKING BRAKE (EXPORT)
REMOVAL - FRONT CABLE...............64
INSTALLATION - FRONT CABLE............64
LEVER - PARKING BRAKE
REMOVAL.............................64
INSTALLATION.........................65
LEVER - PARKING BRAKE (EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE.......................65
INSTALLATION - PARKING BRAKE LEVER
AND FRONT CABLE...................66
SHOES - PARKING BRAKE
REMOVAL.............................67
INSTALLATION.........................72
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 73
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components:
²Brake pedal
²Power brake booster
²Master cylinder
²Brake tubes and hoses
²Proportioning valve (non-ABS vehicles only)
²Disc brakes
²Drum brakes
²Brake lamp switch
²Brake fluid level switch
²Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options.
The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other.
For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly.
The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
come in contact with a hub mounted drum (drum for
disc/drum brakes or drum-in-hat for disc/disc brakes)
and hold it in place.
RSBRAKES - BASE5-3
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Page 151 of 2177

CHRYSLER CARAVAN 2003 Service Manual WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS

WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
rotor or drum, and external surfaces of hub and
bearing assembly.
CAUTION: Handling of brake rotors and calipers
must be done in such a way as to avoid damage to
the rotor and scratching or nicking of brake lining
on the brake shoes.
CAUTION: At no time when servicing a vehicle, can
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled
into the front shock tower in the area shown in (Fig.
1), for the installation of any metal fasteners into
the shock tower. Because of the minimum clear-ance in this area (Fig. 1), installation of metal fas-
teners could damage the coil spring coating and
lead to a corrosion failure of the spring. If a plastic
clip is missing, or is lost or broken during servicing
a vehicle, replace only with the equivalent part
listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
1 - SHOCK TOWER
2 - COIL SPRING
3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL
FASTENERS ARE TO BE INSTALLED INTO SHOCK TOWER IN
THIS AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO
SHOCK TOWER IN THIS SAME AREA.
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)
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Page 152 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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
s

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)
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