Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 155
SERVICE ADJUSTMENTS
INDEX
page
page
Adjusting Rear Service Brakes
. . . . . . . . . . . . . . . . 3
Bleeding Brake System
. . . . . . . . . . . . . . . . . . . . . 5
Brake Hose and Tubing
. . . . . . . . . . . . . . . . . . . . . 7
Master Cylinder Fluid Level
. . . . . . . . . . . . . . . . . . 4
Stop Lamp Switch Adjustment
. . . . . . . . . . . . . . . . 9
Test for Fluid Contamination
. . . . . . . . . . . . . . . . . . 7
Testing Application Adjuster Operation
. . . . . . . . . 10
Wheel Stud Nut Tightening
. . . . . . . . . . . . . . . . . . . 7
ADJUSTING REAR SERVICE BRAKES
Normally, self adjusting drum brakes will not
require manual brake shoe adjustment. Al-
though in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
FRONT WHEEL DRIVE
(1) Raise the vehicle so all wheels are free to turn.
See Hoisting Recommendations in the Lubrication And
Maintenance Section, at the front of this service
manual.
(2) Remove rear brake adjusting hole rubber plug
(Fig. 1), from the rear brake shoe support plate.
(3) Be sure parking brake lever is fully re-
leased. Then back off parking brake cable adjust-
ment so there is slack in the cable.
(4) Insert Brake Adjusting, Special Tool C-3784,
(Fig. 2) or equivalent through the adjusting hole in
support plate and against star wheel of adjusting
screw. Move handle of tool upward until a slight drag is
felt when road wheel is rotated.
(5) Insert a thin screwdriver or piece of welding rod
into brake adjusting hole (Fig. 2). Push adjusting lever
out of engagement with star wheel. Care should be
taken so as not to bend adjusting lever or distort
lever spring. While holding adjusting lever out of
engagement, back off star wheel to ensure a free wheel
with no brake shoe drag.
(6) Repeat above adjustment at the other rear wheel.
Install adjusting hole rubber plugs (Fig. 1) in rear
brake supports.
(7) Adjust parking brake after wheel brake adjust-
ment.
It is important to follow the above sequence to
avoid the possibility of the parking brake system
causing brake drag. This could occur if the park-
ing brakes are adjusted before the service
brakes.
ALL WHEEL DRIVE
(1) Raise the vehicle so all wheels are free to turn.
See Hoisting Recommendations in the Lubrication And
Maintenance Section, at the front of this service
manual.
(2) Be sure parking brake lever is fully re-
leased. Then back off parking brake cable adjust-
ment so there is slack in the cable.
(3) Remove the rear tire and wheel assembly from
the vehicle to expose the front of the rear brake drum.
Fig. 1 Brake Adjusting Hole Plug
Fig. 2 Brake Drum Adjustment With Tool C-3784
.
BRAKES
5 - 3
(4) Rotate the rear brake drum so the adjusting
holes in the face of the brake drum are positioned at
12:00 and 6:00 (Fig. 3).
(5) Insert Brake Adjusting, Special Tool C-3784 (Fig.
4) or equivalent through the adjusting hole in brake
drum and against star wheel of adjusting screw. Move
adjusting tool in a downward motion until a slight drag
is felt when brake drum is rotated.
(6) Then insert a hooked piece of welding rod
through the adjusting hole in brake drum. Hook rod
onto adjusting lever and pull lever out of engagement
with star wheel. While pulling adjustment lever out of
engagement with star wheel, back off star wheel ad-
juster just until there is no contact between brake
shoes and brake drum. Care must be taken so as not
to bend adjusting lever or distort lever spring.
(7) Repeat above adjustment procedure at the other
wheel.
(8) Install the tire and wheel assemblies back on the
vehicle. Install the wheel stud nuts and torque to 129
N
Im (95 ft. lbs.).
(9) Adjust parking brake AFTER wheel brakes are
adjusted.
It is important to follow the above sequence to
avoid the possibility of the parking brake system
causing brake drag. This condition could occur if
the parking brakes are adjusted before the ser-
vice brakes.
MASTER CYLINDER FLUID LEVEL
NON-ABS BRAKES
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Master cylinder reservoirs are marked with the
words fill to bottom of rings indicating proper fluid
level (Fig. 5).
If necessary, add fluid to bring the level to the bottom
of the primary reservoir split ring.
Use only Mopar
t brake fluid or an equivalent from a
sealed container. Brake fluid must conform to DOT 3,
specifications.
DO NOT use brake fluid with a lower boiling point,
as brake failure could result during prolonged hard
braking.
Use only brake fluid that was stored in a tightly-
sealed container.
Fig. 3 Rear Brake Drum Position For Parking Brake
Adjustment (AWD)
Fig. 4 Brake Shoe Adjustment
Fig. 5 Master Cylinder Fluid Level (Non-ABS)
5 - 4
BRAKES
.
DO NOT use petroleum-based fluid because seal
damage will result.
ABS BRAKES
The hydraulic assembly is equipped with a plastic
fluid reservoir with a filter/strainer in the filler neck.
The Anti-Lock brake system requires that the hy-
draulic accumulator be de-pressurized when checking
the fluid level. To check the brake fluid level, the
following procedure should be used:
(1) With the ignition off, de-pressurize the hydraulic
accumulator by applying the brake pedal approxi-
mately 40 times, using a pedal force of approximately
220 N (50 lbs.). A noticeable change in pedal feel will
occur when the accumulator is de-pressurized. Con-
tinue to apply the pedal several times after this change
in pedal feel occurs to insure that the brake system is
fully de-pressurized.
(2) Thoroughly clean both reservoir caps and sur-
rounding area, (Fig. 6) before removing caps. This is to
avoid getting dirt into the reservoir.
(3) Inspect the fluid level, see instructions on top of
reservoir. (TO TOP OF WHITE SCREEN ON FRONT
FILTER/STRAINER.)
(4) Fill with brake fluid to top of screen (Fig. 7) on
the filter/strainer located in brake fluid reservoir. Use
only brake fluid conforming to DOT 3 specifications
such as Mopar
t or equivalent.
(5) Replace reservoir cap.
BLEEDING BRAKE SYSTEM
PRESSURE BLEEDING
Before removing the master cylinder cover, wipe it
clean to prevent dirt and other foreign matter from
dropping into the master cylinder.
Fig. 6 Master Cylinder Fluid Level (W/ABS)
Fig. 7 ABS Reservoir Fill Level On Filter/Strainer
.
BRAKES
5 - 5
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool C-4578 to pressurize the
system for bleeding.
Follow pressure bleeder manufacturer’s instructions,
for use of pressure bleeding equipment.
When bleeding the brake system. Some air may be
trapped in the brake lines or valves far upstream. As
much as ten feet from the bleeder screw (Fig. 8).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes to
ensure all the air gets out.
To bleed the brake system. Attach a clear plastic hose
to the bleeder screw at one wheel and feed the hose into
a clear jar containing fresh brake fluid (Fig. 9).
Next, open the bleeder screw at least one full turn
or more to obtain an adequate flow of brake fluid (Fig.
10).
CAUTION: Just cracking the bleeder screw often
restricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
After 4 to 8 ounces of fluid has been bled through the
brake system. And an air-free flow is maintained in the
clear plastic hose and jar, this will indicate a good
bleed.
Repeat the procedure at all the other remaining
bleeder screws. Then check the pedal for travel. If
pedal travel is excessive or has not been improved.
Enough fluid has not passed through the system to
expel all the trapped air. Be sure to monitor the fluid
level in the pressure bleeder, so it stays at a proper
level so air will not enter the brake system through the
master cylinder.
BLEEDING WITHOUT A PRESSURE BLEEDER
If a pressure bleeder is not available. A good brake
fluid flow can be obtained by manual bleeding of the
brake hydraulic system, following these steps:
(1) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened.
(2) Push the brake pedal toward the floor and hold it
down. Then open the bleeder screw at least 1 full turn.
When the bleeder screw opens the brake pedal will
drop all the way to the floor.
(3) Release the brake pedal only after the bleeder
screw is closed.
(4) Repeat steps 1 through 3, four or five times, at
each bleeder screw. This should pass a sufficient
amount of fluid to expel all the trapped air from the
brake system. Be sure to monitor the fluid level in the
master cylinder, so it stays at a proper level so air will
not enter the brake system through the master cylin-
der.
Test drive vehicle to be sure brakes are operating
correctly and that pedal is solid.
Fig. 8 Trapped Air in Brake Line
Fig. 9 Proper Method for Purging Air From Brake
System (Typical)
Fig. 10 Open Bleeder Screw at Least One Full Turn
(Typical)
5 - 6
BRAKES
.
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