Chrysler PT Cruiser. Manual — part 412
CAUTION: Seal must not be dimpled, stretched, or
out–of–shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Position outer C/V joint sealing boot into its
retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp evenly
on sealing boot.
(9) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975-A and the fol-
lowing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 58). Tighten nut on crimping
tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 59).
(10) Install the halfshaft requiring boot replace-
ment back on the vehicle. (Refer to 3 - DIFFEREN-
TIAL
&
DRIVELINE/HALF
SHAFT
-
INSTALLATION)
Fig. 56 Crimping Tool Installed on Sealing Boot
Clamp
1 - SPECIAL TOOL C-4975A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 57 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 - INTERCONNECTING SHAFT
4 - SEALING BOOT
Fig. 58 Crimping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975A
4 - SEALING BOOT
Fig. 59 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975A
4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
3 - 22
HALF SHAFT
PT
CV BOOT - OUTER (Continued)
BRAKES
TABLE OF CONTENTS
page
page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
BRAKES - BASE
TABLE OF CONTENTS
page
page
BRAKES - BASE
DESCRIPTION - BASE BRAKE SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - BASE BRAKE
STANDARD PROCEDURE - BASE BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . 10
BRAKE FLUID LEVEL SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC/MECHANICAL
DESCRIPTION - DISC BRAKES (FRONT)
DESCRIPTION - DISC BRAKES (REAR)
DESCRIPTION - DRUM BRAKES (REAR)
DIAGNOSIS AND TESTING - DRUM BRAKE
. . . . . . . . . . . . . . . . 16
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
OPERATION - BRAKE TUBES AND HOSES
INSPECTION - BRAKE TUBES AND HOSES
BRAKE PADS/SHOES - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 18
BRAKE PADS/SHOES - REAR DISC
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 20
BRAKE PADS/SHOES - REAR DRUM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 23
DISC BRAKE CALIPER - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 25
INSPECTION - DISC BRAKE CALIPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 27
DISC BRAKE CALIPER - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY - DISC BRAKE CALIPER
(GUIDE PIN BUSHINGS) . . . . . . . . . . . . . . . . 29
DISASSEMBLY - DISC BRAKE CALIPER
(PISTON AND SEAL) . . . . . . . . . . . . . . . . . . . 29
INSPECTION - DISC BRAKE CALIPER
ASSEMBLY - DISC BRAKE CALIPER (GUIDE
PIN BUSHINGS) . . . . . . . . . . . . . . . . . . . . . . 31
(PISTON AND SEAL) . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . 33
DISC BRAKE CALIPER ADAPTER - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 35
DISC BRAKE CALIPER GUIDE PINS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 35
PT
BRAKES
5 - 1
DRUM
DIAGNOSIS AND TESTING - BRAKE DRUM
STANDARD PROCEDURE - BRAKE DRUM
. . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . 37
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
. . . . . . . . . . . . . . . . . . . . . 38
STANDARD PROCEDURE - BRAKE FLUID
. . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . 38
FLUID RESERVOIR
. . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . 39
MASTER CYLINDER
. . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . 45
DISASSEMBLY - CONTINENTAL TEVES
. . . . . . . . . . . . . . . . . . . 46
ASSEMBLY - CONTINENTAL TEVES MASTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION - LHD WITHOUT ABS
. . . . . . . . . . . . . . . . . . 50
PEDAL - WITH AUTOMATIC TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 52
PEDAL - WITH MANUAL TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . 53
POWER BRAKE BOOSTER
. . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING - POWER BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . 57
PROPORTIONING VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . 60
ROTOR
. . . . . . . . . . . . . . . . . . . . . . . . . 61
DIAGNOSIS AND TESTING - BRAKE ROTOR
STANDARD PROCEDURE - BRAKE ROTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION - FRONT BRAKE ROTOR
INSTALLATION - REAR BRAKE ROTOR
BRAKE ROTOR LIMITS/SPECIFICATIONS
SUPPORT PLATE - DRUM BRAKES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . 68
WHEEL CYLINDER - DRUM BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . 69
PARKING BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
STANDARD PROCEDURE - PARKING BRAKE
CABLE - PARKING BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . . . . . 75
LEVER - PARKING BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . 77
SHOES - PARKING BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . 80
5 - 2
BRAKES - BASE
PT
BRAKES - BASE
DESCRIPTION - BASE BRAKE SYSTEM
The base brake system consists of the following
components:
• Brake pedal
• Brake lamp switch
• Power brake booster
• Master cylinder
• Proportioning valves (2) (non-ABS vehicles only)
• Brake tubes and hoses
• Disc brakes (front)
• Disc brakes (rear) (optional)
• Drum brakes (rear)
• Parking brake
The hydraulic brake system is diagonally split on
both the non-antilock and antilock braking systems.
This means the left front and right rear brakes are
on one hydraulic circuit and the right front and left
rear are on the other.
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes as standard equipment. Rear disc brakes and
antilock brakes with or without traction control are
optional.
Vehicles equipped with the optional antilock brake
system (ABS) use a system that shares most base
brake hardware used on vehicles without ABS. For
more information on ABS (Refer to 5 - BRAKES -
ABS - DESCRIPTION).
The parking brake system consists of a hand-oper-
ated lever mounted between the front seats, two
parking brake cables and parking brake shoes at
each rear wheel. Only vehicles with rear disc brakes
receive separate parking brake shoes. Vehicles with
rear drum brakes utilize the service brakes as the
parking brake shoes.
OPERATION - BASE BRAKE SYSTEM
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster’s output rod pushes in the master
cylinder’s primary and secondary pistons applying
hydraulic pressure through the proportioning valves
(non-ABS - rear only) and chassis brake tubes to the
brakes at each tire and wheel assembly.
The parking brakes are hand-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. The parking
brake lever has an automatic-adjusting feature that
takes up any excessive slack in the parking brake
cable system.
WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET
BRAKE
LININGS.
BREATHING
EXCESSIVE
CONCENTRATIONS
OF
ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE
CARE
WHEN
SERVICING
BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS
WITH
COMPRESSED AIR
OR
BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION
CAUTION: Use only Mopar
T
Brake Fluid DOT 3
Motor Vehicle or 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)
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surfaces,
wash it off immediately with water.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean system components. These flu-
ids damage rubber cups and seals.
CAUTION: During service procedures, grease or
any other foreign material must be kept off the cal-
iper assembly, brake linings, brake rotor and exter-
nal surfaces of the hub.
PT
BRAKES - BASE
5 - 3
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