Chrysler Stratus Convertible. Manual — part 189

BRAKE DRUM MACHINING in the SERVICE PRO-
CEDURES section of this service manual group for
refacing procedures.

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. 31).

DRUM BRAKE AUTOMATIC ADJUSTER

Place the vehicle on a frame contact hoist with a

helper in the driver’s seat to apply the brakes. Raise
the vehicle. Remove the adjuster access hole plug,
from the rear brake support plate (Fig. 32). This will
allow access to the star wheel on the automatic
adjuster mechanism. Then, to eliminate the possibil-
ity of maximum adjustment, insert a small screw-
driver through the access hole in the support plate
(Fig. 33) and back off the adjuster star wheel approx-
imately 10 notches. It will be necessary to hold
the adjuster lever away from the star wheel to
perform this adjustment procdure.

Fully apply the brake pedal which will cause the

brake shoes to leave the anchor. Upon application of
the brake pedal, the adjuster lever should move
downward, turning the star wheel on the adjuster.
Thus, a definite rotation of the adjuster star wheel
can be observed if the automatic adjuster is working
properly. If one or more adjusters do not function
properly, the respective brake drum must be removed
for servicing of the adjuster mechanism.

BRAKE FLUID CONTAMINATION

Indications of fluid contamination are swollen or

deteriorated rubber parts.

Swollen rubber parts indicate 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 fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.

If brake fluid is contaminated, drain and thor-

oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.

Fig. 31 Brake Drum Maximum Diameter

Identification

1 – HUB/BEARING ASSEMBLY
2 – WHEEL MOUNTING STUDS
3 – BRAKE DRUM MAXIMUM DIAMETER MARKING
4 – REAR BRAKE DRUM

Fig. 32 Adjuster Access Hole Plug

1 – SHOCK ABSORBER
2 – BRAKE SUPPORT PLATE
3 – KNUCKLE
4 – BRAKE ADJUSTER ACCESS HOLE PLUG

Fig. 33 Accessing The Automatic Adjuster

1 – BRAKE SUPPORT PLATE
2 – BRAKE ADJUSTER ACCESS HOSE
3 – SCREWDRIVER

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BRAKES

5 - 19

DIAGNOSIS AND TESTING (Continued)

BRAKE LAMP SWITCH

The required procedure for testing the brake lamp

switch is covered in GROUP 8H - VEHICLE SPEED
CONTROL SYSTEM in this service manual. The
electrical circuit for brake lamps is covered in
GROUP 8W - REAR LIGHTING in this service man-
ual.

SERVICE PROCEDURES

BRAKE FLUID LEVEL CHECKING

Brake fluid level should be checked a minimum of

twice a year.

Master cylinder reservoirs are marked, FULL and

MIN, indicating the allowable brake fluid level range
in the master cylinder brake fluid reservoir (Fig. 34).

CAUTION: Use only Mopar

T

brake fluid or an equiv-

alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.

Although there is a range, the preferred level is

FULL. If necessary, adjust the brake fluid level,
bringing it to the FULL mark on the side of the mas-
ter cylinder brake fluid reservoir.

BASE BRAKE BLEEDING

NOTE: For bleeding the ABS hydraulic system,
refer to ANTILOCK BRAKE SYSTEM BLEEDING in
the ANTILOCK BRAKE SYSTEM section of this ser-
vice manual group.

CAUTION: Before removing the master cylinder
cap, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder res-
ervoir.

CAUTION: Use only Mopar

T

brake fluid or an equiv-

alent from a fresh, tightly sealed container. Brake
fluid must conform to DOT 3 specifications.

Do not pump the brake pedal at any time while

having a bleeder screw open during the bleeding pro-
cess. This will only increase the amount of air in the
system and make additional bleeding necessary.

Do not allow the master cylinder reservoir to run

out of brake fluid while bleeding the system. An
empty reservoir will allow additional air into the
brake system. Check the fluid level frequently and
add fluid as needed.

The following wheel circuit sequence for bleeding

the brake hydraulic system should be used to ensure
adequate removal of all trapped air from the hydrau-
lic system.

• Left rear wheel

• Right front wheel

• Right rear wheel

• Left front wheel

MANUAL BLEEDING

NOTE: To bleed the brakes manually, the aid of a
helper will be required.

(1) Attach a clear plastic hose to the bleeder screw

and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 35).

(2) Have a helper pump the brake pedal three or

four times and hold it in the down position.

(3) With the pedal in the down position, open the

bleeder screw at least 1 full turn.

(4) Once the brake pedal has dropped, close the

bleeder screw. After the bleeder screw is closed,
release the brake pedal.

(5) Repeat the above steps until all trapped air is

removed from that wheel circuit (usually four or five
times).

(6) Bleed the remaining wheel circuits in the same

manner until all air is removed from the brake sys-
tem. Monitor the fluid level in the master cylinder
reservoir to make sure it does not go dry.

(7) Check the brake pedal travel. If pedal travel is

excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.

(8) Test drive the vehicle to verify the brakes are

operating properly and pedal feel is correct.

Fig. 34 Master Cylinder Fluid Level

1 – CAP
2 – MASTER CYLINDER BRAKE FLUID RESERVOIR
3 – MASTER CYLINDER

5 - 20

BRAKES

JX

DIAGNOSIS AND TESTING (Continued)

PRESSURE BLEEDING

NOTE: Follow

pressure

bleeder

manufacturer’s

instructions for use of pressure bleeding equip-
ment.

Use bleeder tank, Special Tool C-3496-B, with mas-

ter cylinder reservoir adapter, Special Tool 8224, to
pressurize the hydraulic system for bleeding.

Following the same wheel circuit sequence as pre-

scribed for manual bleeding.

(1) Attach a clear plastic hose to the bleeder screw

and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 35).

(2) Open the bleeder screw at least one full turn or

more to obtain a steady stream of brake fluid.

(3) After approximately 4–8 ounces of fluid have

been bled through the brake circuit and an air-free
flow is maintained in the clear plastic hose and jar,
close the bleeder screw.

(4) Repeat this procedure at all the remaining

bleeder screws.

(5) Check the brake pedal travel. If pedal travel is

excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.

(6) Test drive the vehicle to verify the brakes are

operating properly and pedal feel is correct.

MASTER CYLINDER BLEEDING

(1) Clamp the master cylinder in a vise. Attach

Bleeding Tubes, Special Tool 6802 to the master cyl-
inder outlet ports (Fig. 36) or (Fig. 37). Position
bleeding tubes so the outlets of the bleeding tubes
will be below the surface of the brake fluid when res-
ervoir is filled to proper level.

Fig. 35 Proper Method for Purging Air From Brake

System (Typical)

1 – CLEAR HOSE
2 – BRAKE CALIPER
3 – BLEEDER SCREW
4 – CLEAN BRAKE FLUID

Fig. 36 Bleeding Tubes Attached To Master Cylinder

With ABS

1 – MASTER CYLINDER FLUID RESERVOIR
2 – SPECIAL TOOL 6802
3 – MASTER CYLINDER

Fig. 37 Bleeding Tubes Attached to Master Cylinder

With Out ABS

1 – MASTER CYLINDER ASSEMBLY
2 – SPECIAL TOOL 6802

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BRAKES

5 - 21

SERVICE PROCEDURES (Continued)

(2) Fill brake fluid reservoir with brake fluid con-

forming to DOT 3 specifications such as Mopar or an
Equivalent.

(3) Using a wooden dowel per (Fig. 38). Depress

push rod slowly, and then allow pistons to return to
the released position. Continue to repeat this step
several times after no more air bubbles are expelled
from bleed tubes to ensure all air is bled from the
master cylinder.

(4) Remove bleeding tubes from master cylinder

outlet ports, plug outlet ports and install fill cap on
reservoir.

(5) Remove master cylinder from vise.

NOTE: Note: It is not necessary to bleed the brakes
entire hydraulic system after replacing the master
cylinder. However, the master cylinder must have
been thoroughly bled and filled to the proper level
upon installation on the power brake vacuum
booster.

BRAKE TUBE REPAIR

This vehicle use two different size master cylinder

brake tubes.

The master cylinder brake tubes used on this vehi-

cle are different sizes. Vehicles that are not equipped
with antilock brakes use double wall 4.75 mm (3/16
in.) brake tubes at all four port on the master cylin-
der. On vehicles equipped with antilock brakes, the
master cylinder brakes tubes between the master cyl-
inder and the antilock brake hydraulic control unit
are 6.00 mm (1/4 in.).

The chassis brake tubes used on all vehicles is dou-

ble wall 4.75mm (3/16 in.) steel tubing.

When replacing or repairing chassis brake tubes on

this vehicle be sure that the correct size and type of
tube nuts are to be used for replacement of a hydrau-
lic brake tube.

All chassis brake tubes used on this vehicle are

coated with Al-rich/ZN-AL alloy coating to prevent
corrosion of the brake tubes.

Care should be taken when repairing brake tubing,

to be sure the proper bending and flaring tools and
procedures are used, to avoid kinking. Do not route
the tubes against sharp edges, moving components or
into hot areas. All tubes should be properly attached
with recommended retaining clips.

Using Tubing Cutter, Special Tool C-3478-A or

equivalent, cut off damaged seat or tubing (Fig. 39).
Ream out any burrs or rough edges showing on
inside of tubing (Fig. 40). This will make the ends of
tubing square (Fig. 40) and ensure better seating of
flared end tubing. PLACE TUBE NUT ON TUB-
ING BEFORE FLARING THE TUBING.

DOUBLE INVERTED TUBING FLARES

To make a double inverted tubing flare (Fig. 41)

and (Fig. 42). Open handles of Flaring Tool, Special
Tool C-4047 or equivalent. Then rotate jaws of tool
until the mating jaws of tubing size are centered
between vertical posts on tool. Slowly close handles
with tubing inserted in jaws but do not apply heavy
pressure to handle as this will lock tubing in place.

Place gauge (Form A) on edge over end of brake

tubing. Push tubing through jaws until end of tubing
contacts the recessed notch in gauge matching the

Fig. 38 Bleeding Master Cylinder

1 – BRAKE FLUID RESERVOIR
2 – MASTER CYLINDER
3 – WOODEN DOWEL
4 – SPECIAL TOOL 6802

Fig. 39 Cutting And Flaring Of Brake Fluid Tubing

5 - 22

BRAKES

JX

SERVICE PROCEDURES (Continued)