Chrysler PT Cruiser. Manual — part 431

(14) Route the parking brake cable under the car-

peting, up to parking brake cable retaining bracket
on floor pan. Install the parking brake cable through
the retaining bracket. Push the cable in until the
locking fingers on the cable retainer lock the cable
into place.

(15) Install the rear parking brake cables into the

equalizer on the parking brake lever output cable
(Fig. 139).

(16) Ensure that the parking brake cables are cor-

rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.

(17) Raise parking brake handle to full upright

(applied) position.

(18) Keeping your hands clear of the automatic

adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (drill bit or locking pin if a
new mechanism has been installed) (Fig. 138), then
quickly remove it from the parking brake lever mech-
anism. This will allow the park brake lever mecha-
nism to automatically adjust the parking brake
cables.

(19) Install center console and mounting screws.
(20) Install rear window switch panel.
(21) Cycle the parking brake lever once to position

the parking brake cables, then return the parking
brake lever its released position.

(22) Check the rear wheels of the vehicle. They

should rotate freely without dragging with the lever
in its released position.

(23) Apply the parking brake.
(24) Remove the blocks from the tires and wheels.
(25) Reconnect the battery negative terminal.
(26) Reinstall the air cleaner cover (two clips).

LEVER - PARKING BRAKE

REMOVAL

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 19
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.

WARNING:

WHEN

REPAIRS

TO

THE

PARKING

BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER

ADJUSTMENT

MECHANISM

CAN

BE

LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.

WARNING: THE AIRBAG SYSTEM IS A COMPLEX
ELECTROMECHANICAL UNIT. BEFORE ATTEMPT-
ING TO SERVICE ANY COMPONENT NEAR THE
OCCUPANT

RESTRAINT

CONTROLLER

(ORC),

FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE CABLE. ALLOW THE SYSTEM CAPACI-
TOR TO DISCHARGE FOR TWO (2) MINUTES. FAIL-
URE TO DO THIS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Unclip the air cleaner cover (two clips) and

move the cover aside.

(2) Disconnect and isolate the battery negative

cable from its post on the battery.

(3) Block the tire and wheels so the vehicle does

not move once the vehicle parking brake lever is
released.

(4) Remove the transmission shift knob as neces-

sary.

(5) Place parking brake lever in released (full

OFF) position.

(6) Remove screws attaching center console.
(7) Remove rear switch panel from center console.
(8) Working through switch opening, grasp a park-

ing brake cable or equalizer and pull back approxi-
mately 25.4 mm (1 in.)

(9) While holding the cable or equalizer, pull the

parking brake handle to it’s full upright position.

(10) Remove center console.
(11) Grasp the parking brake lever outout cable by

hand and pull upward. Continue pulling cable until
an appropriate pin punch (drill bit or locking pin) can
be inserted sufficiently through hole in left side of
the lever mounting bracket (Fig. 149). This will lock
the barking brake automatic adjustment mechanism
in place and take tension off the parking brake
cables. Slowly release the output cable. There should
now be slack in the cables.

5 - 76

BRAKES - BASE

PT

CABLE - PARKING BRAKE (Continued)

(12) Remove both rear parking brake cables from

the parking brake cable equalizer (Fig. 150).

(13) Remove the wiring harness electrical connec-

tor from the parking brake warning switch on the
right side of the parking brake lever.

(14) Remove the screw and the nut attaching the

parking brake lever to the vehicle (Fig. 151).

(15) Remove the parking brake lever from the

vehicle.

INSTALLATION

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 19

POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.

(1) Place the parking brake lever on the mounting

studs on the vehicle floor. Install and tighten the
screw and the nut to a torque of 28 N·m (250 in. lbs.)
(Fig. 151).

(2) Connect the wiring harness electrical connector

on the parking brake warning switch.

(3) Install both rear park brake cables into the

equalizer on the parking brake lever output cable
(Fig. 150).

(4) Ensure that the parking brake cables are cor-

rectly installed on the equalizer and aligned with the
cable track on the parking brake lever.

(5) Raise parking brake handle to full upright

(applied) position.

(6) Keeping your hands clear of the automatic

adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (drill bit or locking pin if a
new mechanism has been installed) (Fig. 149), then
quickly remove it from the parking brake lever mech-
anism. This will allow the park brake lever mecha-
nism to automatically adjust the parking brake
cables.

(7) Install center console and mounting screws.
(8) Install rear window switch panel.
(9) Cycle the parking brake lever once to position

the parking brake cables, then return the parking
brake lever its released (full OFF) position.

Fig. 149 Pin Punch Installed

1 - PARKING BRAKE LEVER
2 - OUTPUT CABLE
3 - PIN PUNCH

Fig. 150 Parking Brake Cables At Equalizer

1 - LEVER OUTPUT CABLE
2 - EQUALIZER
3 - REAR PARKING BRAKE CABLES

Fig. 151 Parking Brake Lever

1 - PARKING BRAKE LEVER
2 - LEFT CABLE
3 - RIGHT CABLE
4 - EQUALIZER

PT

BRAKES - BASE

5 - 77

LEVER - PARKING BRAKE (Continued)

(10) Check the rear wheels of the vehicle. They

should rotate freely without dragging with the lever
in its released (full OFF) position.

(11) Apply the parking brake.
(12) Remove the blocks from the tires and wheels.
(13) Reconnect the battery negative terminal.
(14) Reinstall the air cleaner cover (two clips).

SHOES - PARKING BRAKE

REMOVAL

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).

(1) Raise the vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(2) Remove the rear tire and wheel assembly.
(3) Remove the rear disc brake caliper assembly

from the brake rotor and store it out of the way.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPER - REMOVAL)

(4) Remove

rear

brake

rotor.

(Refer

to

5

-

BRAKES/HYDRAULIC/MECHANICAL/ROTOR

-

REMOVAL)

(5) Remove the dust cap from the rear hub and

bearing.

(6) Remove the rear hub and bearing assembly

retaining nut and washer.

(7) Remove the rear hub and bearing assembly

from the rear spindle.

(8) Remove the rear brake shoe assembly hold-

down clip (Fig. 152).

(9) Turn the brake shoe adjuster wheel until the

adjuster is at shortest length.

(10) Remove the adjuster assembly from the park-

ing brake shoe assemblies (Fig. 153).

(11) Remove the lower shoe-to-shoe spring (Fig.

154).

(12) Pull the rear brake shoe away from anchor.

Remove the rear brake shoe and upper return spring
(Fig. 155).

(13) Remove the front brake shoe hold-down clip

(Fig. 156). Remove the front brake shoe assembly.

INSTALLATION

NOTE: Perform Step 1 through Step 12 on each
side of the vehicle to complete shoe set installation,
then proceed to Step 13.

(1) Install the front brake shoe and secure it in

place with a hold-down clip (Fig. 156).

(2) Install the rear brake shoe and the upper shoe

return spring (Fig. 155). Pull the rear brake shoe

over the anchor block until it is properly located on
the adapter.

(3) Install the lower shoe-to-shoe return spring

(Fig. 154).

(4) Install the brake shoe adjuster assembly with

the star wheel towards the rear (Fig. 153).

Fig. 152 Rear Brake Shoe Hold-Down Clip

1 - HOLD DOWN CLIP

Fig. 153 Parking Brake Shoe Adjuster Assembly

1 - ADJUSTER

5 - 78

BRAKES - BASE

PT

LEVER - PARKING BRAKE (Continued)

(5) Install the rear brake shoe hold down clip (Fig.

152).

(6) Adjust the parking brake shoes to a diameter

of 171 mm (6.75 inch) (Fig. 157).

(7) Install the rear hub and bearing assembly on

spindle.

(8) Install a new hub and bearing assembly retain-

ing nut. Tighten the retaining nut to a torque of 217
N·m (160 ft. lbs.).

(9) Install the hub and bearing dust cap.

Fig. 154 Brake Shoe Lower Return Spring

1 - LOWER SPRING

Fig. 155 Brake Shoe and Upper Spring

1 - UPPER SPRING
2 - HOLD DOWN CLIP
3 - REAR PARKING BRAKE SHOE

Fig. 156 Front Hold Down Clip And Brake Shoe

1 - FRONT BRAKE SHOE ASSEMBLY
2 - HOLD DOWN CLIP

Fig. 157 Measuring Brake Shoes

1 - REAR PARKING BRAKE SHOES
2 - BRAKE SHOE GAUGE

PT

BRAKES - BASE

5 - 79

SHOES - PARKING BRAKE (Continued)