2005 CHRYSLER CARAVAN wheel

tightening sequence to the full specified torque of 135
N´m (100 ft. lbs.).
(12) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(13) Remove brake pedal depressor tool.
(14) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(15) Lower the vehicle.
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
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. 94). It is a automatic-adjust-
ing type lever.
Vehicles without Fold-in-floor seating have four
flexible steel parking brake cables. They are:
²Front
²Intermediate
²Left rear
²Right rear
Fig. 94 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 - 62 BRAKES - BASERS
SUPPORT PLATE - DRUM BRAKE (Continued)

Vehicles with Fold-in-floor seating have three flex-
ible steel parking brake cables. They are:
²Front
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 cables on vehicles without Fold-in-
floor seating. The equalizer bracket connects the
front parking brake cable to the left rear and right
rear cables on vehicles with Fold-in-floor seating. The
intermediate cable is connected to the right rear
cable on vehicles without Fold-in-floor seating. A
standard cable connector is used to accomplish this
connection.
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-
hat style brake rotor) is used as the parking brake
drum.
DESCRIPTION - EXPORT
The parking brake system on this vehicle features
a hand-operated parking brake lever. The lever is
located between the two front seats and requires a
special front cable.
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
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) Release the parking brake.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) If equipped with Fold-in-floor seating, perform
the following:
(a) Clamp an appropriate pair of locking pliers
on the front parking brake cable strand approxi-
mately 25 mm (1 inch) forward of the button at the
equalizer (Fig. 95).
Fig. 95 Location To Grasp Cable At
RSBRAKES - BASE5-63
PARKING BRAKE (Continued)

CABLE - PARKING BRAKE
INTERMEDIATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
(2) Manually lock out the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
izer, do not remove the locking pliers until
reinstallation of the cable is complete.
(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 108).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 108).
(5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 109). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 109).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank
far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
INSTALLATION
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets.
(2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 108) (Fig. 109).
(3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION).
(4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 109).
(5) Install the intermediate park brake cable on
the cable equalizer (Fig. 108).
(6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables.
(7) Install and position the foam collar on the
parking brake cable to prevent it from rattling
against the vehicle's floor.
(8) Lower the vehicle and apply the park brake
pedal 1 time, this will seat the park brake cables.
Fig. 108 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
Fig. 109 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
RSBRAKES - BASE5-69

CABLE - PARKING BRAKE
REAR
REMOVAL
REMOVAL - RIGHT REAR
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
(2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable.
(4) Create slack in the rear parking brake cables
by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 110).(5) Disconnect the right rear parking brake cable
from the connector on the intermediate cable (Fig.
111).
(6) To remove the right parking brake cable hous-
ing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers (Fig. 112). The alternate method
using an aircraft type hose clamp will not work on
the right side of the vehicle.
Fig. 110 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 111 Right Rear Cable Connection To
Intermediate Cable
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 112 Right Park Brake Cable Removal From
Body Bracket
1 - RIGHT REAR BODY BRACKET
2 - PARK BRAKE CABLE
3 - 14MM WRENCH
4 - LEAF SPRING AND BRACKET
5 - 70 BRAKES - BASERS

(7) Remove the brake shoes from the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
(8) Disconnect parking brake cable from parking
brake actuator lever.
(9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 113).
Remove the cable.
REMOVAL - LEFT REAR
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable.
(4) Create slack in rear park brake cables by lock-
ing out the automatic adjuster as described here.
Grasp an exposed section of front park brake cable
near the equalizer and pull down on it. Then install
a pair of locking pliers on the cable just rearward of
the second body outrigger bracket (Fig. 114).
(5) Disconnect the left rear parking brake cable
from the parking brake cable equalizer (Fig. 115).
Fig. 113 Removing Park Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 114 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 115 Parking Brake Cables At Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
RSBRAKES - BASE5-71
CABLE - PARKING BRAKE REAR (Continued)

(7) Remove the screw fastening the cable to the
rear brake adapter (Fig. 121).
(8) Unhook the cable eyelet from the shoe lever
(Fig. 121).
(9) Slide the cable out of the brake adapter.
(10) Place a 13 mm 12-point box wrench over the
cable retainer at the intermediate bracket as shown
to collapse the retainer fingers (Fig. 122).(11) Pull the cable out of the intermediate bracket
and remove it from the vehicle (Fig. 123).
INSTALLATION
INSTALLATION - RIGHT REAR
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park-
ing brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect the right rear parking brake cable to
the connector on the intermediate parking brake
cable (Fig. 111).
(6) Install the brake drum, then the wheel and tire
assembly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Lower the vehicle.
(9) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
Fig. 121 Cable End At Shoe Lever
1 - SHOE LEVER
2 - SCREW
3 - PARKING BRAKE CABLE
4 - CABLE EYELET
Fig. 122 Cable Removal Using Wrench
1 - CABLE RETAINER
2 - 12-POINT BOX WRENCH
Fig. 123 Cable Intermediate Bracket
1 - FRONT CABLE
2 - INTERMEDIATE BRACKET
3 - LEFT REAR CABLE
4 - RIGHT REAR CABLE
5 - SCREW
5 - 74 BRAKES - BASERS
CABLE - PARKING BRAKE REAR (Continued)

INSTALLATION - LEFT REAR
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park
brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 115).
(6) Install brake drum, and wheel and tire assem-
bly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
INSTALLATION - FOLD-IN-FLOOR SEATING
(1) Pass the leading end of the rear parking brake
cable through the hole in the end of the intermediate
bracket (Fig. 123). Press the cable housing retainer
through the hole until the fingers on the retainer
lock it into place.
(2) Route the cable back toward the brake assem-
bly placing it in the routing clip fastened to the
underbody of the vehicle (Fig. 119). Make sure to
stay to the inside of the left stabilizer bar link while
routing either cable.
(3) If the right rear cable is being serviced, install
screws, attaching the cable routing clamps to the
rear axle (Fig. 120).
(4) Pass the cable through the hole in the brake
adapter and hook the cable eyelet to the shoe lever
(Fig. 121).
(5) Install the screw fastening the cable to the rear
brake adapter (Fig. 121).
(6) Pull straight back on the front cable button
(and pliers) and properly attach the equalizer to all
three parking brake cables (Fig. 118).
(7) Remove the locking pliers from the front park-
ing brake cable and allow the automatic self-adjust-
ing mechanism in the lever to take up any slack.
(8) Lower the vehicle.
(9) Apply and release park brake pedal 1 time.
This will seat the parking brake cables.
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE).
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the steering column cover from the
lower instrument panel.
(6) Remove the reinforcement from the lower
instrument panel.
(7) Remove the three bolts mounting the wiring
junction block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(8) Remove the lower bolt mounting the parking
brake lever (pedal) to the body (Fig. 124).
(9) Remove the forward nut mounting the parking
brake lever to the body (Fig. 124).
(10) Remove the upper bolt mounting the parking
brake lever to the body (Fig. 124).
(11) Pull downward on front parking brake cable
while rotating lever assembly out from behind junc-
tion block.
(12) Remove the release link from the parking
brake lever assembly.
(13) Disconnect the wiring connector from the indi-
cator lamp ground switch (Fig. 124) (Fig. 125).
Fig. 124 Parking Brake Lever Mounting
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RSBRAKES - BASE5-75
CABLE - PARKING BRAKE REAR (Continued)

(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)