brakes DODGE CARAVAN 2006 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 349
5

Towing Requirements
To promote proper break-in of your new vehicle driv-
etrain components the following guidelines are recom-
mended:
CAUTION!
•Avoid towing a trailer for the first 500 miles (805
km) of vehicle operation. Doing so may damage
your vehicle.
•During the first 500 miles (805 km) of trailer
towing, limit your speed to 50 mph (80 km/h).
Perform the maintenance listed in Section 8 of this
manual. When towing a trailer, never exceed the GAWR,
or GCWR, ratings.
WARNING!
Improper towing can lead to an injury accident.
Follow these guidelines to make your trailer towing
as safe as possible:
Make certain that the load is secured in the trailer
and will not shift during travel. When trailering
cargo that is not fully secured, dynamic load shifts
can occur that may be difficult for the driver to
control. You could lose control of your vehicle and
have an accident.
•When hauling cargo or towing a trailer, do not over-
load your vehicle or trailer. Overloading can cause a
loss of control, poor performance or damage to brakes,
axle, engine, transmission, steering, suspension, chas-
sis structure or tires.
358 STARTING AND OPERATING

When replacing tires refer to the Tires–General Infor-
mation section of this manual on Replacement Tires for
proper tire replacement procedures. Replacing tires
with a higher load carrying capacity will not increase
the vehicle’s GVWR and GAWR limits.
Towing Requirements—Trailer Brakes

Donotinterconnect the hydraulic brake system or
vacuum system of your vehicle with that of the trailer.
This could cause inadequate braking and possible
personal injury.
An electronically actuated trailer brake controller is
required when towing a trailer with electronically
actuated brakes. When towing a trailer equipped with
a hydraulic surge actuated brake system, an electronic
brake controller is not required.
Trailer brakes are recommended for trailers over 1,000
lbs (454 kg) and required for trailers in excess of 2,000
lbs (907 kg).
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.
360 STARTING AND OPERATING

WARNING!
Do not connect trailer brakes to your vehicle’s hy-
draulic brake lines. It can overload your brake sys-
tem and cause it to fail. You might not have brakes
when you need them and could have an accident.
Towing any trailer will increase your stopping dis-
tance. When towing you should allow for additional
space between your vehicle and the vehicle in front
of you. Failure to do so could result in an accident.
Towing Requirements—Trailer Lights & Wiring
Whenever you pull a trailer, regardless of the trailer size,
stop lights and turn signals on the trailer are required for
motoring safety.
The Trailer Tow Package may includea4and7pin
wiring harness. Use a factory approved trailer harness
and connector.NOTE:Do not cut or splice wiring into the vehicles
wiring harness.
The electrical connections are all complete to the vehicle
but you must mate the harness to a trailer connector.
Refer to the following illustrations.
4 - Pin Connector
STARTING AND OPERATING 361
5

▫Steering Shaft Seal....................413
▫Steering Linkage......................413
▫Drive Shaft Universal Joints..............413
▫Body Lubrication.....................413
▫Windshield Wiper Blades................414
▫Windshield And Rear Window Washers.....414
▫Exhaust System......................415
▫Cooling System.......................416
▫Hoses And Vacuum/Vapor Harnesses.......421
▫Brakes.............................421
▫Master Cylinder—Brake Fluid Level Check . . 423
▫Fuel System Hoses....................424
▫Automatic Transmission................424▫Front And Rear Wheel Bearings...........428
▫Appearance Care And Protection From
Corrosion...........................428
▫Cleaning The Instrument Panel And Underseat
Cup Holders........................432

Integrated Power Module (IPM)............434

Vehicle Storage........................436

Replacement Light Bulbs.................437

Bulb Replacement......................438
▫Headlights..........................438
▫Front Park/Turn Signal And Sidemarker
Lights.............................439
▫Front Fog Light......................440
394 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 coolant performance, poor gas
mileage, and increased emissions.
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 421
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
422 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—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 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 423
7

Interlock System....................... 310
Reset Mode.......................... 311
Selection Of Lubricant................425,445
Shifting............................. 311
Special Additives...................... 427
Automatic Transmission................... 424
Adding Fluid......................... 426
Fluid and Filter Changes................. 427
Fluid Change......................... 427
Fluid Level Check...................... 426
Fluid Type........................425,445
Ball Joints............................. 412
Battery............................... 409
Gas Caution.......................... 409
Jump Starting......................... 387
Keyless Transmitter Replacement (RKE)....... 25
Saving Feature (Protection)............... 145
Bearings.............................. 428Belts, Drive............................ 405
Body Mechanism Lubrication............... 413
B-Pillar Location........................ 324
Brake Fluid............................ 445
Brake, Parking.......................... 313
Brake System........................314,421
Anti-Lock (ABS)....................... 315
Fluid Check.......................... 423
Hoses.............................. 422
Warning Light........................ 205
Brakes.............................314,421
Brake/Transmission Interlock............... 310
Break-In Recommendations, New Vehicle........ 82
Bulb Replacement....................... 438
Bulbs, Light............................ 437
Calibration, Compass..................... 159
Capacities, Fluid........................ 443
INDEX 483
10

Panic Alarm............................ 23
Parking Brake.......................... 313
Parking On Hill......................... 313
Passing Light........................... 148
Pedals, Adjustable....................... 153
Pets, Transporting........................ 78
Phone, Cellular.......................... 94
Phone, Hands-Free (UConnect™) ............. 94
Placard, Tire and Loading Information......... 324
Power
Brakes.............................. 314
Distribution Center..................... 434
Door Locks........................... 18
Lift Gate............................. 35
Mirrors.............................. 92
Outlet (Auxiliary Electrical Outlet).......... 175
Seats............................... 118
Sliding Door.......................... 30
Steering............................. 317Steering, Checking..................... 412
Sunroof............................. 173
Windows............................. 41
Power Steering Fluid..................... 445
Pregnant Women and Seat Belts.............. 53
Preparation for Jacking.................369,381
Pretensioners
Seat Belts............................. 51
Programmable Electronic Features......164,169,172
Programming Transmitters
(Remote Keyless Entry)...............23,169,172
Radial Ply Tires......................... 331
Radiator Cap (Coolant Pressure Cap).......416,418
Radio Broadcast Signals................... 212
Radio Operation...................234,252,274
Radio Remote Controls.................258,270
Radio, Satellite.......................... 266
Radio (Sound Systems).........214,224,234,244,251
INDEX 493
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