Dodge Caliber. Manual — part 75
BRAKES
TABLE OF CONTENTS
page
page
BRAKES - ABS SERVICE INFORMATION . . . . . . 299
BRAKES - BASE
TABLE OF CONTENTS
page
page
BRAKES - BASE
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . 6
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 12
SWITCH-BRAKE FLUID LEVEL
HYDRAULIC/MECHANICAL
DRUM BRAKE AUTOMATIC ADJUSTER . . . . . . . 18
PADS-FRONT BRAKE
PADS-REAR BRAKE
SHOE AND LININGS-REAR DRUM BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRUM BRAKE SHOE ADJUSTMENT . . . . . . . . . . 34
CALIPER-FRONT DISC BRAKE
CALIPER-REAR DISC BRAKE
DRUM
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . . 51
FLUID
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 55
BRAKE FLUID LEVEL CHECKING . . . . . . . . . . . . 55
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
MASTER CYLINDER
PM
BRAKES
5 - 1
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 57
PEDAL
BOOSTER-POWER BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DIAGNOSIS AND TESTING
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 76
VALVE-PROPORTIONING
ROTOR
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
BRAKE ROTOR MACHINING . . . . . . . . . . . . . . . . . 90
FRONT BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 91
REAR BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . 93
BRAKE ROTOR LIMITS/SPECIFICATIONS . . . . 98
TUBES/HOSES
PLATE-SUPPORT, BRAKE BACKING
WHEEL CYLINDER - DRUM BRAKE
PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
CABLE-PARKING BRAKE
LEVER-PARKING BRAKE
SHOE AND LININGS-PARKING BRAKE
PARKING BRAKE SHOE ADJUSTMENT . . . . . . 127
5 - 2
BRAKES - BASE
PM
BRAKES - BASE
DESCRIPTION - BASE BRAKE SYSTEM
The base brake system consists of the following components:
•
Brake pedal
•
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) (standard)
•
Parking brake
The hydraulic brake system is diagonally split for both the non-antilock and antilock braking systems. That 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 hard-
ware used on vehicles without ABS. For more information on ABS (Refer to 5 - BRAKES - ABS - DESCRIPTION).
The parking brake system consists of a hand-operated lever mounted between the front seats that actuates parking
brake cables connecting to the rear brakes. For more information on Parking Brakes, (Refer to 5 - BRAKES/PARK-
ING BRAKE - DESCRIPTION).
For information on the Stop Lamp Switch, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - DESCRIPTION).
WARNING
WARNING: Dust and dirt accumulating on brake parts during normal use may contain 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 contain 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 containing
asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the
Occupational 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/MECHANICAL/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 min-
eral oil to clean system components. These fluids damage rubber cups and seals.
CAUTION: During service procedures, grease or any other foreign material must be kept off the caliper
assembly, brake linings, brake rotor and external surfaces of the hub.
PM
BRAKES - BASE
5 - 3
CAUTION: When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and
caliper, and scratching or nicking the brake shoe lining.
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR, BRAKE
NOISE and OTHER BRAKE CONDITIONS.
RED BRAKE WARNING INDICATOR
CONDITION
POSSIBLE CAUSES
CORRECTION
RED BRAKE WARNING
INDICATOR ON
1. Parking brake lever not fully
released.
1. Release parking brake lever.
2. Parking brake warning switch on
parking brake lever.
2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir.
3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch.
4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.
5. Refer to Appropriate Diagnostic
Information.
6. ABS EVBP malfunction.
6. Refer to ABS section and Appropriate
Diagnostic Information.
BRAKE NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
DISC BRAKE CHIRP
1. Excessive brake rotor runout.
1. Refer to brake rotor - diagnosis and
testing. Correct as necessary.
DISC BRAKE RATTLE OR
CLUNK
1. Broken or missing spring clips.
1. Replace brake shoes.
2. Caliper guide pin bolts loose.
2. Tighten guide pin bolts.
3. Missing abutment shims.
3. Replace missing abutment shims.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)
1. Brake shoe linings.
1. Replace brake shoes.
DRUM BRAKE CHIRP
1. Lack of lubricant on brake shoe
support plate where shoes ride.
1. Lubricate shoe contact areas on brake
shoe support plates.
2. Wheel cylinder out of alignment.
2. Loosen wheel cylinder mounting bolts,
realign wheel cylinder with brake shoes and
tighten mounting bolts.
DRUM BRAKE CLUNK
1. Drum(s) have threaded machined
braking surface.
1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN
1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.
1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes.
2. Replace rear brake shoes.
5 - 4
BRAKES - BASE
PM
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