brakes DODGE CARAVAN 2005 4.G User Guide

WARNING!
Because the front wheels drive and steer the vehicle,
it is important that you do not exceed the maximum
front or rear GAWR. A dangerous driving condition
can result if either rating is exceeded. You could lose
control of the vehicle and have an accident.
Overloading
The load carrying components (axle, springs, tires,
wheels, etc.) of your vehicle will provide satisfactory
service as long as you do not exceed the GVWR and front
and rear GAWR.
The best way to figure out the total weight of your
vehicle is to weigh it when it is fully loaded and ready for
operation. Weigh it on a commercial scale to insure that it
is not over the GVWR.Figure out the weight on the front and rear of the vehicle
separately. It is important that you distribute the load
evenly over the front and rear axles.
Overloading can cause potential safety hazards and
shorten useful service life. Heavier axles or suspension
components do not necessarily increase the vehicle’s
GVWR.
Loading
To load your vehicle properly, first figure out its empty
weight, axle by axle and side by side. Store heavier items
down low and be sure you distribute their weight as
evenly as possible. Stow all loose items securely before
driving. If weighing the loaded vehicle shows that you
have exceeded either GAWR, but the total load is within
the specified GVWR, you must redistribute the weight.
Improper weight distribution can have an adverse effect
on the way your vehicle steers and handles and the way
the brakes operate.
STARTING AND OPERATING 337
5

A load equalizing hitch is recommended for loaded
trailer weights above 1,000 lbs (454 kg) and required for
weights above 2,000 lbs (907 kg).
Special care should be taken when towing a trailer with
heavy duty trailer tow package, without a load equaliz-
ing hitch, and with 6 to 7 passengers, to insure the rear
GAWR is not exceeded. Depending on your vehicle
model and options, the maximum trailer weight could
range from 0 to 2000 pounds.
CAUTION!
If the trailer weighs more than 1,000 lbs (454 kg)
loaded, it should have its own brakes and they
should be of adequate capacity. Failure to do this
could lead to accelerated brake lining wear, higher
brake pedal effort, and longer stopping distances.
WARNING!
Connecting trailer brakes to your vehicle’s hydraulic
brake lines can overload your brake system and
cause it to fail. You might not have brakes when you
need them and could have an accident.
STARTING AND OPERATING 341
5

▫Steering Shaft Seal....................391
▫Steering Linkage......................391
▫Drive Shaft Universal Joints..............391
▫Body Lubrication.....................391
▫Windshield Wiper Blades................392
▫Windshield And Rear Window Washers.....392
▫Exhaust System......................393
▫Cooling System.......................394
▫Hoses And Vacuum/Vapor Harnesses.......399
▫Brakes.............................399
▫Master Cylinder—ABS Brakes Brake
Fluid Level Check.....................401
▫Fuel System Hoses....................402▫Automatic Transmission................402
▫Front And Rear Wheel Bearings...........406
▫Appearance Care And Protection
From Corrosion......................406
▫Cleaning The Instrument Panel And Underseat
Cup Holders........................410

Integrated Power Module (IPM)............412

Vehicle Storage........................415

Replacement Light Bulbs.................415

Bulb Replacement......................416
▫Headlights..........................416
▫Front Park/Turn Signal And
Sidemarker Lights.....................418
▫Front Fog Light......................419
372 MAINTAINING YOUR VEHICLE

•Do not change the thermostat for summer or winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory cooling performance.
•Increasing engine speed at idle does not reduce cool-
ant temperature! Put transmission in NEUTRAL and
let engine idle at normal engine idle speed.
Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.
Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.Brakes
In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Schedules.
MAINTAINING YOUR VEHICLE 399
7

WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn’t have your full
braking capacity in an emergency.
Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
NOTE:Often, fluid such as oil, power steering fluid,
and brake fluid are used during assembly plant opera-
tions to facilitate the assembly of hoses to couplings.
Therefore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping of
hot fluid when systems are under pressure (during
vehicle operation), should be noted before hose is re-
placed based on leakage.
NOTE:Inspection of brake hoses should be performed
whenever the brake system is serviced and every engine
oil change. Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If there is any evidence
of cracking, scuffing, or worn spots, the hose should be
400 MAINTAINING YOUR VEHICLE

replaced immediately! Eventual deterioration of the hose
can take place resulting in a possibility of a burst failure.
WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
Master Cylinder—ABS Brakes Brake Fluid Level
Check
The fluid level in the master cylinder should be checked
when performing underhood services, or immediately if
the brake system warning light indicates system failure.
Clean the top of the master cylinder area before removing
the cap. Add fluid to bring the level up to the top of the
“FULL”mark on the side of the master cylinder reservoir.Overfilling of fluid is not recommended because it may
cause leaking in the system.
Add enough fluid to bring the level up to the require-
ments described on the brake fluid reservoir. With disc
brakes, fluid level can be expected to fall as the brake
pads wear. However, low fluid level may be caused by a
leak and a checkup may be needed.
Use only manufacturers recommended brake fluid, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.WARNING!
Use of brake fluid that may have a lower initial
boiling point or unidentified as to specification, may
result in sudden brake failure during hard pro-
longed braking. You could have an accident.
MAINTAINING YOUR VEHICLE 401
7

Interlock System....................... 298
Reset Mode.......................... 299
Selection Of Lubricant................403,423
Shifting............................. 299
Special Additives...................... 405
Automatic Transmission................... 402
Adding Fluid......................... 404
Fluid and Filter Changes................. 405
Fluid Change......................... 405
Fluid Level Check...................... 404
Fluid Type........................403,423
Ball Joints............................. 390
Battery............................... 387
Gas Caution.......................... 387
Jump Starting......................... 365
Keyless Transmitter Replacement............ 26
Saving Feature (Protection)............... 137
Bearings.............................. 406Belts, Drive............................ 383
Body Mechanism Lubrication............... 391
B-Pillar Location........................ 312
Brake Fluid............................ 423
Brake, Parking.......................... 301
Brake System........................302,399
Anti-Lock........................... 303
Fluid Check.......................... 401
Hoses.............................. 400
Warning Light........................ 197
Brakes.............................302,399
Brake/Transmission Interlock............... 298
Break-In Recommendations, New Vehicle........ 82
Bulb Replacement....................... 416
Bulbs, Light............................ 415
Calibration, Compass..................... 152
Capacities, Fluid........................ 421
INDEX 459
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Phone, Cellular.......................... 96
Phone, Hands-Free....................... 96
Placard, Tire and Loading Information......... 313
Power
Brakes.............................. 302
Distribution Center..................... 412
Door Locks........................... 18
Lift Gate............................. 36
Mirrors.............................. 94
Outlet.............................. 168
Seats............................... 108
Sliding Door.......................... 31
Steering............................. 305
Steering, Checking..................... 390
Sunroof............................. 165
Windows............................. 39
Power Steering Fluid..................... 423
Pregnant Women and Seat Belts.............. 52
Preparation for Jacking.................347,359Pretensioners
Seat Belts............................. 50
Programmable Electronic Features......156,160,164
Programming Transmitters............23,160,164
Radial Ply Tires......................... 320
Radiator Cap (Coolant Pressure Cap).......395,396
Radio Broadcast Signals................... 205
Radio Operation...................217,234,261
Radio Remote Controls.................246,258
Radio, Satellite.......................... 254
Radio (Sound Systems)...........206,216,226,233
Rear Air Conditioning.................270,279
Rear Cup Holder........................ 172
Rear Heater............................ 270
Rear Seat Removal....................124,126
Rear Seating Flexibility.................128,130
Rear Window Defroster................... 287
Rear Window Features.................... 284
INDEX 469
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