2005 Dodge Grand Caravan Brake Rotor – Removal an
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Filed Under (Dodge) by admin on 18-07-2010
REMOVAL – FRONT BRAKE ROTOR 1. Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. 2. Remove the front wheel and tire assembly. 3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle. 4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove any retainer clips from the wheel mounting studs. 6. Remove brake rotor from hub by pulling it straight off wheel mounting studs. INSTALLATION – FRONT BRAKE ROTOR 1. Install the brake rotor back on the hub and bearing. 2. Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle. 3. Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 Nm (125 ft. lbs.) torque. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.) . 5. Lower vehicle to the ground.
Filed Under (Ford) by admin on 04-03-2011
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. For additional information, refer to Section 204-04. 3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. Support the caliper using mechanic’s wire. Remove and discard the guide pin bushings. Inspect the guide pin threads for damage, install new guide pin(s) as necessary. 4. Remove the brake pads from the caliper. 5. Inspect the brake pads for wear or contamination and install new pads as necessary. For additional information, refer to General Procedures in Section 206-00. 6. Using a C-clamp and a worn brake pad, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional information, refer to General Procedures in Section 206-00. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as shown. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings. Install the guide pin bushings into the caliper bores. Install the guide pins into the bushings. 3. Install the brake pads to the caliper. 4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. To install, tighten to 38 Nm (28 lb-ft). Clean and dry guide pin threads as necessary. 5. Fill the master cylinder with clean, specified brake fluid. 6. Install the wheel and tire. For additional information, refer to Section 204-04. 7. Apply the brake several times to verify correct brake operation.
Filed Under (Chrysler) by admin on 01-12-2010
1. Remove master cylinder fluid reservoir cap. 2. Raise and support vehicle. 3. Remove tire and wheel assembly. CAUTION: DO NOT overtighten C-clamp. 4. Place appropriately sized C-clamp over brake caliper, placing screw-drive head against outboard shoe and hook against rear of caliper. Slowly tighten screw-drive retracting caliper pistons into bores and brake outboard brake shoe free from caliper fingers. See Fig. 22 . Remove C-clamp. 5. Once outboard shoe is free from caliper fingers, slide caliper inboard on guides providing clearance between the rotor and inboard brake shoe. 6. Slide an appropriate prying tool through center opening in top of caliper behind brake shoe between 2 caliper pistons. Use care not to come in contact with pistons or dust boots potentially damaging them. Pry against rear of inboard brake shoe braking it free from caliper pistons. 7. Remove the 2 brake caliper guide pin bolts. See Fig. 23 . 8. Remove disc brake caliper from brake adapter and hang out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this. 9. Remove brake shoes from disc brake caliper adapter. See Fig. 27 . 10. Install master cylinder fluid reservoir cap. Installation (Front) 1. Place brake shoes in anti-rattle clips on adapter. See Fig. 27 . Make sure clips are properly installed. See Fig. 26 . 2. Install disc brake caliper over brake shoes on brake caliper adapter. See CALIPER . 3. Align guide pin bolt holes with guide pins and install caliper guide pin bolts. See TORQUE SPECIFICATIONS . 4. Install tire and wheel assembly. See TORQUE SPECIFICATIONS . 5. Lower vehicle. 6. Pump brake pedal several times to seat shoes to caliper and brake rotor. 7. Check and fill brake fluid level as necessary. See CHECKING & FILLING under BRAKE FLUID in SERVICE. 8. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes.
Filed Under (Ford) by admin on 02-02-2011
Remote release handle Parking brake control Parking brake rear cable and conduit clip (part of 2A635) Parking brake cable bracket Parking brake rear cable and conduit— (LH) Parking brake rear cable and conduit— (RH) Parking brake cable equalizer Front parking brake cable and conduit Front parking brake cable clip The parking brake system is actuated when the parking brake control (2780) is depressed. The parking brake control applies tension to the front parking brake cable and conduit (2853) and parking brake cable equalizer (2A602). The parking brake cable equalizer is coupled to the RH parking brake rear cable and conduit (2A635) and the LH parking brake rear cable and conduit. The respective rear brake assemblies are then applied. The rear wheel brake assembly contains a cable-actuated parking brake assembly. The parking brake releases the rear brakes using a remote release lever incorporated with the parking brake control. If the parking brake control is not fully released, the parking brake signal switch will illuminate the brake warning light. The parking brake signal switch is mounted on the parking brake control. The switch is held in place by a self-tapping screw and aligned with a locater pin. The drum brake parking brake system is self-adjusting, therefore cable tension does not need to be adjusted. Rear Disc Brakes Parking Brake Components, Rear Disc Brakes
Filed Under (Ford) by admin on 08-03-2011
Master Cylinder Priming — In-Vehicle or Bench WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal (2455) action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder (2140) has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder (2140) in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir (2K478), and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal (2455), or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional information, refer to Section 206-06. 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Master Cylinder Priming — 4.6L 1. CAUTION: Use only bleed screws on the engine side of the brake master cylinder (2140). The hydro-boost bleed screw, located near the dash on the hydro-booster casting, is for the booster cavity filled with power steering fluid, not brake fluid. Connect a clear waste line to the bleed screw closet to the booster first and the other end in a container partially filled with recommended brake fluid.