Chrysler PT Cruiser. Manual — part 421
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(3) Install the disc brake caliper over the brake
shoes on the brake caliper adapter. Make sure the
springs on the shoes do not get caught in the hole
formed into the center of the caliper housing.
(4) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
61).
(5) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(6) Lower the vehicle.
(7) Pump the brake pedal several times before
moving the vehicle to set the shoes to the brake
rotor.
DRUM
DIAGNOSIS AND TESTING - BRAKE DRUM
With the drum off the vehicle, measure the drum
for diameter variation (oval shape). The diameter
variation of the drum braking surface must not
exceed specifications listed in the following table.
Measure brake drum runout. Brake drum runout
should be checked with the drum mounted on a
brake lathe. Brake drum runout should not exceed
specifications listed in the following table.
If either of these measurements are not within
specification, reface or replace the drum. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DRUM
-
STANDARD PROCEDURE).
Always replace the drum if machining will cause
the diameter to exceed drum maximum diameter. All
brake drums are marked with the maximum allow-
able brake drum diameter (Fig. 63). Maximum brake
drum diameter can also be found in the following
table.
BRAKE DRUM LIMITS
SALES
CODE
DIAMETER
VARIATION
RUNOUT
RUNOUT
(IN 360°)
MAXIMUM
DIAMETER
BRB/
BRK
0.080 mm
0.003 in.
0.045
mm in
60°
0.002
in. in
60°
0.130
mm
0.005 in.
230.60 mm
9.079 in.
Note: Vehicles without ABS are equipped with BRB drum
brakes. Vehicles with ABS are equipped with BRK drum
brakes.
STANDARD PROCEDURE - BRAKE DRUM
MACHINING
If a brake drum is deeply scored or warped, it can
be machined on a brake lathe equipped to machine
brake drums. Follow the manufacturers instructions
on the machining procedure.
Measure the brake drum diameter before machin-
ing. If machining the drum will cause the drum to
exceed maximum allowable diameter, do not machine
the brake drum. It needs to be replaced.
CAUTION: Do not machine the brake drum if it will
cause the drum to exceed maximum allowable
diameter.
All brake drums are marked with the maximum
allowable brake drum diameter.All vehicles have it
marked on the inside of the drum (Fig. 63).
When machining, make sure the feed rate for the
final cut is set to deliver a fine finish. A fine finish
helps to avoid a screw effect on the brake shoes when
the brakes are applied. This final feed cut specifica-
tion varies from lathe manufacturer to lathe manu-
facturer.
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).
Fig. 63 Drum Maximum Diameter Identification
(Inside Drum)
1 - MAXIMUM DIAMETER IDENTIFICATION MARKING
2 - BRAKE DRUM
5 - 36
BRAKES - BASE
PT
DISC BRAKE CALIPER GUIDE PINS (Continued)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove rear tire and wheel assembly.
(3) Remove
brake
drum
retaining
clips
(if
equipped) (Fig. 64).
(4) Slide brake drum off mounted wheel studs of
hub and remove from vehicle (Fig. 64). If drum does
not come off, further brake clearance can be obtained
by removing rubber plug near top of support plate
and backing off brake adjuster screw. To do so:
(a) Fabricate pawl release tool like one shown
using a coat hanger or heavy mechanics wire (Fig.
65).
(b) Remove plug from rear of support plate
below wheel cylinder.
(c) Insert fabricated tool through access hole in
support plate, under adjuster, against lever pawl
(Fig. 66). Pawl is attached to and pivots from lead-
ing shoe. When inserting tool through hole, direct-
ing tool somewhat forward (toward leading shoe)
assures better contact with pawl.
(d) While pushing on pawl with fabricated tool
to disengage it from adjuster star-wheel teeth (Fig.
66), rotate star-wheel downward to back off adjust-
ment using a small screwdriver or brake adjuster
tool.
(e) Once adjuster screw is backed off a sufficient
amount, drum should slide off wheel studs.
INSTALLATION
NOTE: Before installing drum, inspect brake shoe
linings for wear, alignment, and contamination.
Repair or replace as necessary.
NOTE: If rust or any foreign material is present on
hub, drum or wheel mating surfaces, wet wire brush
these areas to remove prior to assembly of parts.
(1) Properly remove any buildup formed along
outer edge of drum’s machined braking surface.
(2) Adjust brake shoes to drum diameter using a
brake shoe gauge. (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/BRAKE
PADS/SHOES
-
ADJUSTMENTS)
Fig. 64 Drum Brakes (Typical)
1 - WHEEL CYLINDER
2 - SEAL
3 - SUPPORT PLATE
4 - BRAKE SHOES
5 - RETAINER CLIP
6 - DUST CAP
7 - NUT
8 - DRUM
9 - HUB AND BEARING
Fig. 65 Fabricated Tool
1 - APPROXIMATELY 15 CM (6 INCHES)
2 - THIS END TO BE INSERTED INTO BRAKE ASSEMBLY
Fig. 66 Fabricated Tool Inserted Against Pawl
1 - ACCESS HOLE
2 - STAR WHEEL
3 - LEVER PAWL
4 - FABRICATED TOOL
PT
BRAKES - BASE
5 - 37
DRUM (Continued)
(3) Install brake drum on rear hub and bearing
(Fig. 64).
(4) Install tire and wheel assembly. Tighten wheel
mounting nuts to 135 N·m (100 ft. lbs.) torque.
(5) Lower vehicle.
(6) Road test vehicle stopping in both forward and
reverse directions. Automatic-adjuster will continue
to adjust brakes as necessary during road test.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If the fluid sep-
arates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If the brake fluid is contaminated, drain and thor-
oughly flush the brake system. Replace all the rubber
parts or components containing rubber coming into
contact with the brake fluid including: the master
cylinder and reservoir; proportioning valves (non-
ABS);
caliper
seals;
wheel
cylinder
seals; ABS
hydraulic control unit; and all hydraulic fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING
NOTE: Brake fluid level should be checked a mini-
mum of twice a year.
Master cylinder reservoirs are marked, FULL and
ADD, indicating the allowable brake fluid level range
in the master cylinder fluid reservoir (Fig. 67).
CAUTION: Use only Mopar
T
Brake Fluid DOT 3
Motor Vehicle or an equivalent from a tightly sealed
container.
Do
not
use
petroleum-based
fluid
because seal damage in the brake system will
result. (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/FLUID - SPECIFICATIONS)
Although there is a range, the preferred level is
FULL. As necessary, adjust the brake fluid level to
the FULL mark listed on the side of the master cyl-
inder fluid reservoir (Fig. 67). Do not overfill the sys-
tem.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar
t Brake Fluid DOT 3 Motor Vehicle or an
equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
Fig. 67 Fluid Level Markings
1 - RESERVOIR
2 - MASTER CYLINDER
5 - 38
BRAKES - BASE
PT
DRUM (Continued)
FLUID RESERVOIR
REMOVAL - BOSCH
NOTE: The Bosch master cylinder does not need to
be removed from the power brake booster for
removal and installation of the brake fluid reservoir.
The Continental Teves master cylinder requires
removal from the power brake booster for removal
and installation of the brake fluid reservoir. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL) (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER CYLINDER - DIS-
ASSEMBLY)
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).
(1) Clean the master cylinder housing and brake
fluid reservoir exterior surfaces.
(2) Remove the brake fluid reservoir cap. Using a
clean syringe or siphoning tool, empty as much brake
fluid as possible from the reservoir.
(3) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 79).
(4) Remove the two plastic pins holding the reser-
voir to the master cylinder (Fig. 68).
(5) Lift the reservoir from the master cylinder
casting.
(6) Remove the grommets (O-rings) sealing the
reservoir to the master cylinder housing (Fig. 69).
INSTALLATION - BOSCH
(1) Install NEW sealing grommets (O-rings) in the
master cylinder housing (Fig. 69).
(2) Lubricate the sealing grommets with fresh
clean brake fluid. Place the reservoir in position over
the grommets making sure the filler hole is towards
the front of the vehicle. Seat the reservoir into the
grommets. While holding the reservoir firmly against
the grommets, install new plastic pins through their
mounting holes until they protrude out the other side
of the master cylinder reservoir (Fig. 68).
(3) Connect the brake fluid level switch wiring
connector (Fig. 79).
(4) Fill the reservoir with fresh clean brake fluid.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID - STANDARD PROCEDURE).
MASTER CYLINDER
DESCRIPTION
Two different manufacturers are used for this com-
ponent. Early production PT27 (convertible) use mas-
ter cylinders supplied by Bosch. Normal production
vehicles (PT27 and PT44) use master cylinders sup-
plied by Continental Teves. The master cylinder
brands are not interchangeable.
The individual brands can be easily identified by
the shape of the fluid reservoir. Bosch master cylin-
ders use a more rounded reservoir while Continental
Teves master cylinders use a larger, more squared-off
look reservoir.
Fig. 68 Master Cylinder Reservoir
1 - BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 - RESERVOIR RETAINING PINS
3 - SEAL
Fig. 69 Sealing Grommets
1 - MASTER CYLINDER
2 - GROMMETS (O-RINGS)
3 - SEAL
PT
BRAKES - BASE
5 - 39
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст