shaft CHRYSLER CARAVAN 2002 Repair Manual

OUTPUT FLANGE SEAL
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear halfshaft inner joint at differen-
tial output flange (Fig. 54).
(3) Using two screwdrivers and wood blocks to pro-
tect differential housing casting, pry output flange
out of differential (Fig. 55).
(4) Use suitable screwdriver to remove output
flange seal (Fig. 56).
Fig. 54 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 55 Output Flange Removal
1 - WOOD BLOCK
2 - PRYBAR
3 - OUTPUT SHAFT
4 - PRYBAR
5 - WOOD BLOCK
6 - DIFFERENTIAL CASE
Fig. 56 Output Flange Seal Removal
1 - OUTPUT FLANGE SEAL
2 - SCREWDRIVER
3 - 48 REAR DRIVELINE MODULERS
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INSTALLATION
(1) Install output flange seal to differential hous-
ing using tool C4171A and 8493 (Fig. 57).
(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) Install and torque bolts to 61 N´m (45 ft. lbs.)
(Fig. 58).
(5) Check differential assembly fluid level and
adjust as required. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/REAR DRIVELINE MODULE/FLUID -
STANDARD PROCEDURE)
Fig. 57 Output Flange Seal Installation
1 - DRIVER HANDLE C4171
2 - INSTALLER 8493
Fig. 58 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
RSREAR DRIVELINE MODULE3-49
OUTPUT FLANGE SEAL (Continued)
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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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(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 23).
(4) Remove rear caliper from adapter using the fol-
lowing 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. 24).(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
25).
(6) If the brake rotor needs to be removed it can be
removed by removing the retainer clips and then
pulling the rotor straight off the wheel mounting
studs.
(7) Remove the outboard brake shoe from the cali-
per. Brake shoe is removed by pushing the shoe
toward the piston, disengaging the two metal protru-
sions on the shoe back, then sliding the brake shoe
off the caliper.
(8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 26).
Fig. 23 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 24 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
Fig. 25 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
5 - 20 BRAKES - BASERS
BRAKE PADS/SHOES - REAR DISC (Continued)
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DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers.
(2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out.
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 47). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.
Fig. 45 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 46 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 - BASE5-31
DISC BRAKE CALIPER - REAR (Continued)
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(14) Disconnect PRNDL cable from shift lever and
column bracket (Fig. 66).
(15) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 66).(16) Remove pinch side clip, then remove shift
cable from bracket on column.
(17) Turn the steering wheel from the STRAIGHT-
AHEAD position 180É to the right (upside-down posi-
tion), then remove the key and lock the column in
place.
(18) Remove the pinch bolt securing column cou-
pling to intermediate shaft (Fig. 67).
Fig. 64 Steering Column Shrouds
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 65 Pedal Switch Wiring Connector
1 - STEERING COLUMN FIXED SHROUD
2 - BRAKE TRANSMISSION SHIFT INTERLOCK
3 - B.T.S.I. WIRING CONNECTOR
4 - PEDAL SWITCH WIRING CONNECTOR
Fig. 66 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE
5 - STEERING COLUMN
Fig. 67 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
5 - 44 BRAKES - BASERS
PEDAL - ADJUSTABLE (Continued)
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(19) Loosen two lower column mounting nuts.
(20) Remove two upper column mounting nuts.
(21) Remove the steering column.
(22) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 68).
(23) Remove two nuts securing brake lamp switch
bracket to pedal assembly (Fig. 69). Remove bracket.(24) Disconnect pedal wiring harness connector
(Fig. 69).
(25) Remove pedal wiring harness from clips along
pedal bracket.
(26) Position a small screwdriver between the cen-
ter tang on the power brake booster input rod-to-
brake pedal pin retaining clip (Fig. 70).
(27) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(28) Slide booster input rod off pedal pin.
(29) Remove the four nuts attaching power brake
booster to dash panel (Fig. 71).
(30) Remove two brake pedal upper mounting bolts
at instrument panel dash bracket (Fig. 71).
(31) Disconnect accelerator cable retainer at accel-
erator pedal; remove cable from pedal.
(32) Remove adjustable brake pedal assembly.
INSTALLATION
(1) Install adjustable brake pedal assembly under
instrument panel.
(2) Install two brake pedal upper mounting bolts
at instrument panel dash bracket (Fig. 71). Do not
fully tighten at this time.
(3) Install four nuts attaching power brake booster
to dash panel (Fig. 71).
Fig. 68 Intermediate Shaft Dash Seal And Silencer
Shell
1 - INTERMEDIATE SHAFT
2 - DASH SEAL
3 - SILENCER SHELL
Fig. 69 Brake Lamp Switch Bracket
1 - BRAKE LAMP SWITCH BRACKET
2 - PEDAL WIRING HARNESS CONNECTOR
3 - STEERING COLUMN INTERMEDIATE SHAFT
4 - BRACKET MOUNTING NUTS
Fig. 70 Input Rod Brake Pedal Retaining Clip
Removal
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
RSBRAKES - BASE5-45
PEDAL - ADJUSTABLE (Continued)
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(4) Tighten four booster mounting nuts and two
pedal bracket upper mounting bolts to 28 N´m (21 ft.
lbs.) torque.
(5) Install accelerator cable to pedal; install cable
retainer at accelerator pedal.
(6) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 72).
(7) Install wiring harness in clips along pedal
bracket, then connect harness to pedal wiring har-
ness connector (Fig. 69).
(8) Install brake lamp switch bracket on pedal
assembly (Fig. 69). Tighten mounting nuts to 6 N´m
(50 in. lbs.) torque.(9) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
68).
(10) Install the steering column on the mounting
studs. Install the two upper and two lower mounting
nuts. Tighten the upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque.
(11) Install the column shaft coupling onto the
intermediate shaft and install the pinch bolt (steer-
ing column should still be locked position it was
placed in during removal). Make sure the rounded
side of the intermediate shaft is matched to the cur-
vature of the coupling. Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(12) Attach shift cable housing to bracket on col-
umn.
(13) Connect shift cable end to shift lever mecha-
nism pin (Fig. 66).
(14) Connect PRNDL cable to end of shift lever
mechanism pin and column bracket (Fig. 66).
(15) Connect column wiring harness connectors to
SKIM (if equipped), BTSI solenoid, ignition switch,
halo lamp, multi-function switch, and clockspring.
(16) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(17) If equipped, connect traction control off switch
wiring connector.
(18) Install upper shroud (with traction control off
switch if equipped) (Fig. 64).
(19) Connect adjustable pedal switch wiring con-
nector along left side of column (Fig. 65).
(20) Install the lower shroud with adjustable pedal
switch. Install screws fastening steering column
shrouds to steering column (Fig. 64).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(21) Install and adjust NEW brake lamp switch.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION)
(22) Install instrument panel lower left reinforce-
ment (Fig. 63).
(23) Attach hood release to lower left reinforce-
ment.
(24) Install knee blocker reinforcement plate (Fig.
62).
(25) Connect parking brake release link to release
handle.
(26) Install data link diagnostic connector to
mounting hole in reinforcement plate.
Fig. 71 Booster Mounting (Typical)
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 72 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
5 - 46 BRAKES - BASERS
PEDAL - ADJUSTABLE (Continued)
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(27) Install lower steering column cover/knee
blocker (Fig. 62).
(28) Install silencer panel below lower steering col-
umn cover/knee blocker.
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery in following manor:
(a) Connect scan tool (DRBIIIt) to data link
diagnostic connector located below steering column.
(b) Turn ignition key to ON position. Exit vehi-
cle with scan tool leaving scan tool harness
plugged in.
(c) Ensuring that there are no occupants in vehi-
cle, connect ground (-) cable to the negative post of
the battery.
(d) Using scan tool, read and record any airbag
fault codes. Refer to Appropriate Diagnostic Infor-
mation if any faults are found.
(e) Through drivers open window, Reach around
back of steering wheel (between steering wheel and
instrument cluster) and turn ignition key to OFF,
then back ON while observing instrument cluster
airbag indicator lamp. It should go on for six to
eight seconds, then go out. This action indicates
that airbag system is functioning normally. If air-
bag indicator lamp fails to light, blinks on and off,
or goes on and stays on, there is an airbag system
malfunction. Refer to Appropriate Diagnostic Infor-
mation to diagnose the system malfunction.
(30) Using scan tool (DRBIIIt), check for and clear
any existing adjustable pedal fault codes. The adjust-
able pedal system is now activated.
(31) Turn key to OFF and remove scan tool from
vehicle.
(32) Test operation of adjustable pedals, memory
seats (if equipped), RKE (if equipped), and all func-
tions that are steering column operated. If applica-
ble, reset the radio and the clock.
(33) Road test the vehicle to ensure proper opera-
tion of the steering and brake systems.
PEDAL TORQUE SHAFT - RHD
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
(3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Removethe link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled.
(4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 73). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled.
(5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig.
74).
(6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 74).
(7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
INSTALLATION
(1) Lubricate both ends of the torque shaft with
MS-4517 Lubricant or equivalent and install the
torque shaft from the left side reversing the removal
procedure.
(2) Install the brake booster bracket on the left
end of the shaft.
(3) Install the four brake booster retaining nuts
inside the passenger compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(4) Install the retaining nut for the brake booster
bracket in the engine compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(5) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod. Also coat the surface of
Fig. 73 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
RSBRAKES - BASE5-47
PEDAL - ADJUSTABLE (Continued)
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the brake pedal torque shaft pin where it contacts
the brake pedal link.
CAUTION: When installing the power brake booster
input rod on the brake pedal torque shaft pin, do
not reuse the old retaining clip.
(6) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 73).
CAUTION: When installing the brake pedal link on
the brake pedal torque shaft pin, do not reuse the
old retaining clip.
(7) Connect the brake pedal link to the torque
shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(10) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(11) Road test vehicle to ensure proper operation of
the brakes.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster mounts on the engine
compartment side of the dash panel. It is connected
to the brake pedal by the input (push) rod (Fig. 75).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
Fig. 74 BOOSTER, TORQUE SHAFT AND PEDAL
MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT
Fig. 75 Power Brake Booster (Typical)
1 - VACUUM CHECK VALVE
2 - POWER BRAKE BOOSTER ASSEMBLY
3 - INPUT ROD
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - OUTPUT ROD
5 - 48 BRAKES - BASERS
PEDAL TORQUE SHAFT - RHD (Continued)
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