2005 CHRYSLER CARAVAN brake rotor

DISASSEMBLY - CALIPER PISTON AND
SEAL...............................24
CLEANING - CALIPER...................25
INSPECTION - CALIPER..................25
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (CONTINENTAL TEVES
BRAKES)............................25
ASSEMBLY - CALIPER PISTON AND SEAL . . 26
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (CONTINENTAL TEVES
BRAKES)............................27
INSTALLATION - FRONT DISC BRAKE
CALIPER (TRW BRAKES)...............27
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....28
DISASSEMBLY - CALIPER PISTON AND SEAL..28
CLEANING - CALIPER...................29
INSPECTION - CALIPER..................29
ASSEMBLY - CALIPER PISTON AND SEAL . . . 30
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 (TRW BRAKES)..................31
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (TRW BRAKES).............32
DRUM
REMOVAL.............................32
INSTALLATION.........................32
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................33
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................33
SPECIFICATIONS
BRAKE FLUID........................33
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK..33
OPERATION - NON-ABS JUNCTION BLOCK . . 33
REMOVAL - NON-ABS JUNCTION BLOCK....34
INSTALLATION - NON-ABS JUNCTION BLOCK..34
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................35
DESCRIPTION - RHD..................35
OPERATION...........................36
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................36
REMOVAL
REMOVAL - LHD......................36
REMOVAL - RHD......................37DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................38
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................39
INSTALLATION
INSTALLATION - LHD..................39
INSTALLATION - RHD..................39
PEDALS - ADJUSTABLE
REMOVAL.............................40
INSTALLATION.........................43
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................44
INSTALLATION.........................44
POWER BRAKE BOOSTER
DESCRIPTION.........................45
OPERATION...........................46
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................46
REMOVAL
REMOVAL - LHD......................46
REMOVAL - RHD......................48
INSTALLATION
INSTALLATION - LHD..................50
INSTALLATION - RHD..................51
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................53
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................53
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................54
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................55
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................55
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 55
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................58
REMOVAL - FRONT BRAKE ROTOR........59
INSTALLATION - FRONT BRAKE ROTOR.....59
SPECIFICATIONS
BRAKE ROTOR.......................60
BRAKE ROTOR - EXPORT..............60
SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................61
INSTALLATION.........................61
WHEEL CYLINDERS
REMOVAL.............................62
INSPECTION..........................62
INSTALLATION.........................62
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................62
DESCRIPTION - EXPORT...............63
OPERATION...........................63
5 - 2 BRAKES - BASERS

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
shoes and braking surfaces of brake rotor or drum,
and external surfaces of hub and bearing assembly.
CAUTION: Brake rotor and caliper handling must be
done in such a way as to avoid damage to the rotor,
especially the machined surfaces, and scratching or
nicking of the brake linings.
CAUTION: Only the recommended jacking or hoist-
ing procedures for this vehicle are to be used
whenever it is necessary to lift a vehicle. Failure to
raise a vehicle utilizing the recommended lift points
can result in damage to the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING - STAN-
DARD PROCEDURE)
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.
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.
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)

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).
SCRAPING (METAL-TO-
METAL).1. Foreign object interference with
brakes.1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
RSBRAKES - BASE5-5
BRAKES - BASE (Continued)

OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. 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.
BRAKES DRAG (FRONT
OR ALL)1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent.5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY)1. Parking brake cables binding or
froze up.1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes.2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only).3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted.Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.2. Refer to power brake booster
diagnosis and testing.
EXCESSIVE PEDAL
EFFORT1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist
(vacuum leak).2. Refer to power brake booster
diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
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.
5 - 6 BRAKES - BASERS
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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.
RSBRAKES - BASE5-7
BRAKES - BASE (Continued)

REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 3).
(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. 3).
ADJUSTABLE PEDALS
SWITCH
REMOVAL
The adjustable pedals switch is located in the
steering column lower shroud. Remove the shroud,
then remove the switch. (Refer to 19 - STEERING/
COLUMN/LOWER SHROUD - REMOVAL)
INSTALLATION
The adjustable pedals switch is located in the steer-
ing column lower shroud. Install the switch in the
shroud, then install the shroud. (Refer to 19 - STEER-
ING/COLUMN/LOWER SHROUD - INSTALLATION)
Once installed, test for proper operation of the
adjustable pedals.
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
Each front disc brake consists of the following com-
ponents:
²Brake Rotor
²Brake Caliper
²Brake Caliper Adapter
²Shoes (Pads)
There are two non-interchangeable front disc brake
systems. One is manufactured by TRW and the other
by Continental Teves.
CAUTION: Components used on the TRW brakes
are not interchangeable with the Continental Teves
brakes. The two different systems must not be
mixed. Improper performance, noise and increased
stopping distance can occur.
The TRW front brake caliper is a one piece casting
containing a single 66 mm diameter piston bore (Fig.
4) with a phenolic piston. The caliper mounts to a
caliper adapter using two guide pin bolts that thread
into guide pins slid into the caliper adapter (Fig. 5).
The pins are lubricated and have boots that seal
them in place in the adapter.
Fig. 3 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. 4 Front Disc Brake Calipers
1 - CONTINENTAL TEVES CALIPER (66 mm bore)
2 - TRW CALIPER (66 mm bore)
3 - GUIDE PIN BOLT
4 - GUIDE PIN AND BOOT
5 - CALIPER ADAPTER
6 - GUIDE PIN BOLT
7 - GUIDE PIN BUSHING
8 - CALIPER ADAPTER
RSBRAKES - BASE5-11
BRAKE FLUID LEVEL SWITCH (Continued)

The Continental Teves front brake caliper is a one
piece casting containing a single piston 66 mm diam-
eter bore (Fig. 4) with a phenolic piston. The caliper
mounts to a caliper adapter using two guide pin bolts
that thread into the caliper adapter and slide on
bushings mounted in the caliper.
CAUTION: TRW and Continental Teves calipers are
not interchangeable. Each caliper is specifically
designed for the unique brake system. If calipers
are interchanged, improper performance, noise and
increased stopping distance can occur.
The two different brake calipers use different
devices to control rattling. While the TRW brakes use
spring clips that mount at the ends of the shoes in
the adapters, Continental Teves brakes use a clip on
the rear of the inboard pad to hold it to the piston
and a larger clip on the outside of the caliper, holding
it to the adapter (Fig. 6).
All brake caliper adapters mount to the steering
knuckle in the same way using two mounting bolts.
The brake rotors are also different depending on
brake system. The TRW front brakes utilize an
inverted-hat style rotor. This rotor is externally
vented meaning the inner most diameter of the brak-
ing disc vents to the outboard side (or face) of the
rotor (Fig. 7). The Continental Teves front brakes uti-
lize the familiar internally-vented hat style rotor.
Internally-vented refers to the fact that the inner
most diameter of the braking disc vents to the
inboard side of the rotor (Fig. 7).CAUTION: Do not mix rotor types on the same vehi-
cle. If brake rotors are mixed, noise and wear prob-
lems can result.
Fig. 5 Guide Pins And Boots
1 - PINS
2 - BOOTSFig. 6 Anti-Rattle Devices On Calipers
1 - CONTINENTAL TEVES CALIPER
2 - TRW CALIPER
3 - ANTI-RATTLE CLIP
4 - ANTI-RATTLE CLIP
Fig. 7 Externally and Internally Vented Rotors
(Cross-Sectional View)
1 - EXTERNAL VENTS (TRW and Continental Teves BR3)
2 - INTERNAL VENTS (Continental Teves BRE)
5 - 12 BRAKES - BASERS
HYDRAULIC/MECHANICAL (Continued)

DESCRIPTION - DISC BRAKES (REAR)
There are several distinctive features to the rear
disc brakes on this vehicle (Fig. 8). The single piston,
floating caliper rear disc brake system includes a hub
and bearing assembly, adapter, rotor, caliper, and
brake shoes.
This vehicle is equipped with a caliper having a 42
mm (1.65 in.) piston and uses a 15 inch solid non-
vented brake rotor. The brake rotor is described as a
drum-in-hat style because of its dual role as a brak-
ing disc and parking brake drum.
The parking brake system on vehicles equipped
with rear disc brakes consists of a small duo-servo
drum brake mounted to the caliper adapter and uses
the interior of the rear disc brake rotor as a drum
(hat section of drum-in-hat style brake rotor).
The outboard rear disc brake shoes (pads) are side-
oriented. The shoes are marked indicating which side
they belong on.
DESCRIPTION - DISC BRAKES (EXPORT)
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.
DESCRIPTION - DRUM BRAKES (REAR)
This vehicle's rear wheel drum brakes are a two-
shoe, internal-expanding type with an automatic
adjuster screw. The automatic adjuster screw is
located directly below the wheel cylinder that is
mounted near the top of the brake assembly (Fig. 9).
These and two brake shoes (and attaching parts) are
mounted to a support plate at each rear wheel. A
brake drum covers each brake assembly.
OPERATION
OPERATION - DISC BRAKES (FRONT)
When the brakes are applied, fluid pressure is sent
to each brake caliper. The pressure at the caliper is
exerted equally against the caliper piston. The pres-
sure applied to the piston is transmitted directly to
the inboard brake shoe. This forces the shoe lining
against the inner surface of the brake rotor. At the
same time, fluid pressure within the caliper piston
bore forces the caliper to slide inward on its guide
pins. This action brings the outboard shoe lining into
contact with the outer surface of the brake rotor.
This pressure on both sides of the brake rotor causes
friction, bringing the vehicle to a stop.
When the brake pedal is released, so is the fluid
pressure. The piston seal inside the caliper is
designed to pull the piston back into the bore of the
caliper when the brake pedal is released (Fig. 10).
This action helps maintain the proper brake shoe-to-
rotor clearance.
Fig. 8 Rear Disc Brakes
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 9 Drum Brake Assembly (Right Shown)
1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
3 - AUTOMATIC ADJUSTER LEVER
4 - TENSION CLIP
5 - AUTOMATIC ADJUSTER ASSEMBLY
RSBRAKES - BASE5-13
HYDRAULIC/MECHANICAL (Continued)