2005 CHRYSLER CARAVAN brakes

LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) 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. 126).
(3) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 127).
(4) Remove the equalizer from the front parking
brake cable.
(5) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever mechanism to rotate around to
its stop and remove the tension from the adjuster
and front park brake cable.
(6) Remove the front parking brake cable housing
from body outrigger bracket. Cable is removable by
sliding a 14 mm box wrench over the cable retainer
and compressing the three retaining fingers.Alter-
nate method:Use an aircraft type hose clamp and
screwdriver.
(7) Remove the four mounting nuts from the bot-
tom of the parking brake lever bracket.
(8) Lower vehicle.
(9) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)(10) If equipped with a manual transaxle, remove
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- REMOVAL)
(11) Unhook the end of the parking brake cable
from the lever mechanism.
(12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers.
(13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment.
(14) Lift the parking brake lever and slide the
parking brake cable out.
(15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle.
(2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket.
(3) Hook the end of the parking brake cable on the
parking brake lever mechanism.
(4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan.
(5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION)
Fig. 126 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 127 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
RSBRAKES - BASE5-77

(6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place.
(9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place.
(10) 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.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 127).
(12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables.
(13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake.The park-
ing 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) AWD only - Remove the cotter pin and nut
retainer (Fig. 128) from the stub shaft of the outer
C/V joint.
(5) AWD only - Remove the spring washer (Fig.
129) from the stub shaft of the outer C/V joint.
Fig. 128 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 129 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
5 - 78 BRAKES - BASERS
LEVER - PARKING BRAKE (EXPORT) (Continued)

(6) AWD only - Remove the hub nut and washer
(Fig. 130) from the stub shaft of the outer C/V joint.
(7) Release the parking brake.
(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. 131).(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 132).
(10) Remove rear caliper from adapter using the
following procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 133).
Fig. 130 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 131 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 132 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 133 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
RSBRAKES - BASE5-79
SHOES - PARKING BRAKE (Continued)

(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
134).
(12) Remove the rotor from the hub/bearing.
(13) Remove the park brake cable mounting bolt to
adapter.
(14) Remove the end of the park brake cable from
the actuator lever on the adapter (Fig. 135).(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. 136) to com-
press the locking tabs on the park brake cable
retainer.
(16) AWD only - Remove ABS wheel speed sensor
head from hub/bearing (Fig. 137).
Fig. 134 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 135 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. 136 Park Brake Cable Removal From Adapter
1 - DRIVESHAFT
2 - 1/2º WRENCH
3 - PARK BRAKE CABLE
4 - PARK BRAKE CABLE RETAINER
5 - ADAPTER
Fig. 137 Speed Sensor Attaching Bolt (AWD)
1 - ADAPTER
2 - TONE WHEEL
3 - WHEEL SPEED SENSOR
4 - AXLE
5 - BOLT
6 - DRIVESHAFT
5 - 80 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

(17) FWD only - Remove the ABS wheel speed sen-
sor from the hub/bearing in the following fashion:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 138).
(b) Push up on metal retaining clip (Fig. 138)
until it bottoms. This will release wheel speed sen-
sor head from hub and bearing. While holding
metal clip up, pull back on wheel speed sensor
head removing it from hub and bearing.
(c) Remove wheel speed sensor from hub/bear-
ing.
(18) Remove the hub/bearing-to-axle mounting
bolts (Fig. 139).(19) Remove the hub/bearing (Fig. 140).
Fig. 138 Sensor Connection At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 139 Hub/Bearing Mounting Bolts (AWD Shown)
1 - DRIVESHAFT
2 - MOUNTING BOLTS
3 - AXLE
4 - MOUNTING BOLTS
5 - ADAPTER
Fig. 140 Hub/Bearing Removal/Installation (AWD
Shown)
1 - PARK BRAKE BRAKE SHOE
2 - OUTER C/V JOINT
3 - HUB/BEARING
4 - PARK BRAKE BRAKE SHOE
5 - STUB SHAFT
RSBRAKES - BASE5-81
SHOES - PARKING BRAKE (Continued)

CAUTION: Corrosion may occur between the hub/
bearing and the axle flange. If this occurs, the hub/
bearing will be difficult to remove from the axle and
disc brake caliper adapter. If the hub/bearing will
not come out by pulling on it by hand, don't not
pound on it with a hammer. Pounding on the hub/
bearing will damage it. To remove a hub/bearing
that is corroded in place, lightly tap the disc brake
caliper adapter using a soft-face hammer. This will
remove both the caliper adapter and hub/bearing
together from the axle. With a helper supporting the
caliper adapter in his hands, position Remover,
Special Tool 8214-1, on the cast housing of hub/
bearing (Fig. 141). Do not position the special tool
on the inner race of hub/bearing. Lightly strike the
Remover with a hammer to remove the hub/bearing
from the caliper adapter.
(20) Remove the adapter from the rear axle.
(21) Mount the adapter in a vise using the anchor
boss for the park brake cable (Fig. 142).
(22) Remove the lower return spring (Fig. 143)
from the leading and trailing park brake shoes.
Fig. 141 Hub/Bearing Removal From Caliper Adapter
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
Fig. 142 Adapter Mounted In Vise
1 - ADAPTER
2 - PARK BRAKE CABLE BOSS
3 - VISE
4 - PARK BRAKE BRAKE SHOES
Fig. 143 Lower Return Spring
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - RETURN SPRING
4 - TRAILING PARK BRAKE SHOE
5 - 82 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

(23) Remove the hold down spring and pin (Fig.
144) from the leading park brake shoe.
(24) Remove the adjuster (Fig. 145) from the lead-
ing and trailing park brake shoe.(25) Remove the leading park brake shoe (Fig.
146) from the adapter. Leading brake shoe is
removed by rotating the bottom of the brake shoe
inward (Fig. 146) until the top of the brake shoe can
be removed from the brake shoe anchor. Then remove
the upper return springs (Fig. 146) from the leading
brake shoe.
(26) Remove the upper return springs (Fig. 147)
from the trailing park brake shoe.
Fig. 144 Leading Brake Shoe Hold Down Pin And
Spring
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - ALLEN WRENCH
4 - HOLD DOWN SPRING/PIN
Fig. 145 Brake Shoe Adjuster
1 - LEADING PARK BRAKE SHOE
2 - ADJUSTER
3 - TRAILING PARK BRAKE SHOE
Fig. 146 Primary Brake Shoe Remove/Install
1 - PARK BRAKE ACTUATOR
2 - ANCHOR
3 - LEADING PARK BRAKE SHOE
4 - UPPER RETURN SPRINGS
5 - TRAILING PARK BRAKE SHOE
Fig. 147 Upper Return Springs
1 - TRAILING PARK BRAKE SHOE
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - UPPER RETURN SPRINGS
RSBRAKES - BASE5-83
SHOES - PARKING BRAKE (Continued)

(27) Remove the hold down spring and pin (Fig.
148) from the trailing park brake shoe.
(28) Remove the trailing park brake shoe from the
adapter.
(29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(3) Install the hold down spring and pin (Fig. 148)
on the trailing park brake shoe.
(4) Install the upper return springs (Fig. 147) on
the trailing park brake shoe.
(5) Install the upper return springs on the leading
park brake shoe (Fig. 146). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter.
(6) Install the adjuster (Fig. 145) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.(7) Install the hold down spring and pin (Fig. 144)
on the leading park brake shoe.
(8) Install the lower return spring (Fig. 143) on
the leading and trailing park brake shoes.When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 143).
(9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle.
(10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 149).
(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 140).
(12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.).
(13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 137). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs).
(14) FWD only - Install the wheel speed sensor in
the following fashion:
(a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
Fig. 148 Trailing Brake Shoe Hold Down Pin And
Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
Fig. 149 Adapter Installed On Mounting Bolts (AWD
Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
5 - 84 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)