ABS CHRYSLER CARAVAN 2002 Owner's Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2002Pages: 2399, PDF Size: 57.96 MB
Page 100 of 2399
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
(1) Place crimping tool C-4975-A over bridge of
clamp (Fig. 21).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 22).
LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the
retaining clamp.
(1) Place prongs of clamp locking tool in the holes
of the clamp (Fig. 23).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 24).
(16) Install the half shaft into the vehicle. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT
- INSTALLATION)
Fig. 21 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 22 Sealing Boot Retaining Clamp Installed -
Typical
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975-A
4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
Fig. 23 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT
3 - SEALING BOOT
Fig. 24 Sealing Boot Clamp Correctly Installed
1 - INNER TRIPOD JOINT HOUSING
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SEALING BOOT
RSHALF SHAFT - REAR3-21
CV BOOT - INNER/OUTER (Continued)
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BI-DIRECTIONAL
OVERRUNNING CLUTCH
DESCRIPTION
The bi-directional overrunning clutch (BOC) (Fig.
28) works as a mechanical disconnect between the
front and rear axles, preventing torque from being
transferred from the rear axle to the front. The BOC
is a simply an overrunning clutch which works in
both clockwise and counter-clockwise rotations. This
means that when the output (the rear axle) is rotat-
ing faster in one direction than the input (front axle),
there is no torque transmission. But when the input
speed is equal to the output speed, the unit becomes
locked. The BOC provides significant benefits regard-
ing braking stability, handling, and driveline durabil-
ity. Disconnecting the front and the rear driveline
during braking helps to maintain the braking stabil-
ity of an AWD vehicle. In an ABS/braking event, the
locking of the rear wheels must be avoided for stabil-
ity reasons. Therefore brake systems are designed to
lock the front wheels first. Any torque transfer from
the rear axle to the front axle disturbs the ABS/brak-
ing system and causes potential instabilities on aslippery surface. The BOC de-couples the rear driv-
eline as soon the rear wheels begin to spin faster
than the front wheels (front wheels locked) in order
to provide increased braking stability. Furthermore
the BOC also reduces the likelihood of throttle off
over-steer during cornering. In a throttle off maneu-
ver, the BOC once again de-couples the rear driveline
forcing all the engine brake torque to the front
wheels. This eliminates the chance of lateral slip on
the rear axle and increases it on the front. The vehi-
cle will therefore tend to understeer, a situation
which is considered easier to manage in most circum-
stances. During this maneuver, and during the ABS
braking event, the BOC does not transmit torque
through to the rear wheels. The rear driveline mod-
ule, with the BOC, will perform the same as a front
wheel drive vehicle during these events. The gear
ratio offset between the front and rear differentials
force the BOC into the overrunning mode most of the
time. This allows BOC to significantly reduce the
rolling resistance of the vehicle, which improves fuel
consumption, allows the downsizing of the driveline
components, and prevents the PTU and propshaft
joints from overheating.
3 - 36 REAR DRIVELINE MODULERS
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STEADY STATE, HIGH SPEED, NO WHEEL SLIP
The roller cage positions the rollers on the input shaft
flats during low and high speed overrunning and during
initial BOC lockup. The roller cage is rotating at input
shaft (propeller shaft) speed at all times. At low speeds,
the friction shoes (Fig. 31) are pressed against the fric-
tion ground via the garter spring (Fig. 32), creating a
drag force on the roller cage. The drag force positions
the cage, which in turn positions the rollers to one side
of the flat. The direction of this drag force (position of
the roller) is dependent on the input (propeller shaft)
rotational direction. Since the rollers are always in con-
tact with the outer race, due to centrifugal forces, the
rollers want to follow the outer race due to drag. During
overrunning operation, the outer race is rotating faster
than the input; causing the rollers to want to traverse
the flat from one side to the other. During low speeds,
the brake shoes counteract this effect. To avoid exces-
sive wear, the ground shoes are designed to lift off from
the friction ground due to centrifugal forces at higher
rotational speeds.
To keep the rollers in the overrunning position and
avoid undesired9high speed lockup9, a high speed
latch (Fig. 33) positions the cage before the ground
shoes lift off. A further explanation of the high speed
effects follows as well. Utilizing only the friction
shoes approach means that at high speed the
required ground shoe drag torque would cause exces-
sive brake shoe wear or the roller will begin tomigrate to the opposite side of the flat due to the
drag force of the outer race. This would result in sys-
tem lock-up. (Fig. 34) shows the BOC as it crosses
the speed where the brake shoe force is overcome by
the roller drag on the outer race. Notice that the
roller is locking up on the opposite side of the flat
and the cage supplies no force on the rollers.
Fig. 31 Front View of BOC
1 - GARTER SPRING
2 - FRICTION BRAKE SHOES
3 - FRICTION GROUND CONNECTED TO GROUND TAB
4 - INPUT SHAFT
Fig. 32 Location of the Grounding Element
1 - DIFFERENTIAL HOUSING
2 - GROUND TAB
3 - GARTER SPRING
Fig. 33 BOC High Speed Latch (Not Engaged)
1 - TOOTH (TWO PLACES)
2 - GARTER SPRING
3 - TABS AT BOTH ENDS FIT INTO SLOTS IN CAGE
4 - TWO PART DESIGN
RSREAR DRIVELINE MODULE3-39
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)
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At high speed, the rollers are forced outward to the
outer race because of centrifugal force. At high
speeds, the friction shoes can no longer prevent lock-
up. When the teeth on the high-speed latch engage
into the input shaft, it keeps the rollers centered
above the flats because the tabs on the latch are
locked into the cage. (Fig. 36) shows the roller config-
uration with the High-Speed Latch engaged.
On the BOC shaft, the high speed latch teeth lock
up in the grooved areas, shown in (Fig. 37), when the
turning speed reaches the critical value. (Fig. 37)
also shows the outer race/viscous coupler. Notice the
surface (outer race) the rollers mate against when
transferring torque.
DIFFERENTIAL ASSEMBLY
DESCRIPTION
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
OPERATION
In operation, power flow occurs as follows:
²The pinion gear rotates the ring gear²The ring gear (bolted to the differential case)
rotates the case
²The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
²The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig.
38).
Fig. 36 BOC Operation at High Speed with High
Speed Latch
Fig. 37 BOC Input Shaft
1 - GROOVED AREA (2 LOCATIONS)
2 - ROLLER MATING SURFACE
Fig. 38 Differential OperationÐStraight Ahead
Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
RSREAR DRIVELINE MODULE3-41
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)
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BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 85
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..................9
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................10
ADJUSTABLE PEDAL SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SWITCH.......................11
REMOVAL.............................11
INSTALLATION.........................12
PEDAL POSITION SENSOR
DESCRIPTION.........................12
DIAGNOSIS AND TESTING - PEDAL
POSITION SENSOR....................13
REMOVAL.............................13
INSTALLATION.........................13
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 14
DESCRIPTION - DISC BRAKES (REAR)....15
DESCRIPTION - DISC BRAKES (EXPORT) . . 15DESCRIPTION - DRUM BRAKES (REAR) . . . 16
OPERATION
OPERATION - DISC BRAKES (FRONT).....16
OPERATION - DISC BRAKES (REAR)......16
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................16
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES . 17
OPERATION - BRAKE TUBES AND HOSES . . . 17
INSPECTION - BRAKE TUBES AND HOSES . . . 17
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)..................17
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES).................18
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES.............................19
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DRUM BRAKES)...........19
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....19
CLEANING - DISC BRAKE SHOES..........21
INSPECTION - DISC BRAKE SHOES........21
INSTALLATION - REAR DISC BRAKE SHOES . . 21
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....22
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................25
INSTALLATION - REAR DRUM BRAKE SHOES . 25
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................26
RSBRAKES5-1
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DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)..................26
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES).................26
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........27
DISASSEMBLY - CALIPER PISTON AND
SEAL...............................27
CLEANING - CALIPER...................28
INSPECTION - CALIPER..................28
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........28
ASSEMBLY - CALIPER PISTON AND SEAL . . 28
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DISC BRAKES)...........29
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DRUM BRAKES)..........30
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....30
DISASSEMBLY - CALIPER PISTON AND SEAL . 31
CLEANING - CALIPER...................32
INSPECTION - CALIPER..................32
ASSEMBLY - CALIPER PISTON AND SEAL . . . 32
INSTALLATION - REAR DISC BRAKE CALIPER . 33
DISC BRAKE CALIPER ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER...........................34
INSTALLATION - FRONT DISC BRAKE
CALIPER ADAPTER....................34
DISC BRAKE CALIPER GUIDE PINS
REMOVAL - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES).............34
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (DISC/DRUM BRAKES).......34
DRUM
REMOVAL.............................35
INSTALLATION.........................35
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................35
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................35
SPECIFICATIONS
BRAKE FLUID........................35
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK . 36
OPERATION - NON-ABS JUNCTION BLOCK . . 36
REMOVAL - NON-ABS JUNCTION BLOCK....36
INSTALLATION - NON-ABS JUNCTION BLOCK . 36
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................37DESCRIPTION - RHD..................38
OPERATION...........................38
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................38
REMOVAL
REMOVAL - LHD......................39
REMOVAL - RHD......................40
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................40
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................41
INSTALLATION
INSTALLATION - LHD..................41
INSTALLATION - RHD..................42
PEDAL - ADJUSTABLE
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SYSTEM......................43
REMOVAL.............................43
INSTALLATION.........................45
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................47
INSTALLATION.........................47
POWER BRAKE BOOSTER
DESCRIPTION.........................48
OPERATION...........................49
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................49
REMOVAL
REMOVAL - LHD......................50
REMOVAL - RHD......................52
INSTALLATION
INSTALLATION - LHD..................53
INSTALLATION - RHD..................55
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................56
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................57
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................57
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................58
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................59
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 59
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................61
REMOVAL - FRONT BRAKE ROTOR........62
INSTALLATION - FRONT BRAKE ROTOR.....62
SPECIFICATIONS
BRAKE ROTOR.......................63
BRAKE ROTOR - EXPORT..............63
5 - 2 BRAKES - BASERS
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SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................64
INSTALLATION.........................64
WHEEL CYLINDERS
REMOVAL.............................65
INSPECTION..........................65
INSTALLATION.........................65
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................65
DESCRIPTION - EXPORT...............66
OPERATION...........................66
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................66
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................67
CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE
(FRONT)............................67
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)......................68
REMOVAL - PARKING BRAKE CABLE
(RIGHT REAR)........................69
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)..............................70INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)............................71
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)......................71
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)........................72
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR).........................72
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 72
CABLES - PARKING BRAKE (EXPORT)
REMOVAL - FRONT CABLE...............72
INSTALLATION - FRONT CABLE............72
LEVER - PARKING BRAKE
REMOVAL.............................72
INSTALLATION.........................73
LEVER - PARKING BRAKE (EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE.......................74
INSTALLATION - PARKING BRAKE LEVER
AND FRONT CABLE...................75
SHOES - PARKING BRAKE
REMOVAL.............................75
INSTALLATION.........................81
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 83
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
RSBRAKES - BASE5-3
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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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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)
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Page 138 of 2399
(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)
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