Chrysler Stratus Convertible. Manual - part 184

SPECIFICATIONS

TORQUE SPECIFICATIONS

DESCRIPTION

TORQUE

Caliper To Knuckle Bolts . . . . . 31 N·m (23 ft. lbs.)
Driveshaft Nut . . . . . . . . . . . 142 N·m (105 ft. lbs.)
Front Wheel Lug Nuts . . . . . . 135 N·m (100 ft. lbs.)
Knuckle To Ball Stud Nut . . . . . 95 N·m (70 ft. lbs.)
Tie Rod End To Knuckle . . . . . . 61 N·m (45 ft. lbs.)

SPECIAL TOOLS

DRIVESHAFT

Tie Rod Remover MB-991113

Boot Clamp Installer C-4975A

DIFFERENTIAL AND DRIVELINE

3 - 17

BRAKES

TABLE OF CONTENTS

page

BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1

ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . 75

BASE BRAKE SYSTEM

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

DIAGNOSIS AND TESTING

BASE BRAKE SYSTEM DIAGNOSIS CHARTS . . . 10
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 13
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . 14
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DRUM BRAKE AUTOMATIC ADJUSTER. . . . . . . . 19
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 19
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 20

SERVICE PROCEDURES

BRAKE FLUID LEVEL CHECKING . . . . . . . . . . . . 20
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 20
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 21
BRAKE TUBE REPAIR . . . . . . . . . . . . . . . . . . . . . 22
BRAKE ROTOR MACHINING . . . . . . . . . . . . . . . . 23
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 24

REMOVAL AND INSTALLATION

SERVICE WARNINGS AND CAUTIONS . . . . . . . . 25
BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 27
BRAKE FLUID LEVEL SWITCH . . . . . . . . . . . . . . 29
POWER BRAKE BOOSTER (2.5L ENGINE) . . . . . 30

(WITH REAR DISC BRAKES) . . . . . . . . . . . . . . 61

BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 62

DISASSEMBLY AND ASSEMBLY

MASTER CYLINDER BRAKE FLUID

RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

DISC BRAKE CALIPER (FRONT AND REAR) . . . . 64
DRUM BRAKE WHEEL CYLINDER (REAR) . . . . . 69

CLEANING AND INSPECTION

DISC BRAKES (FRONT). . . . . . . . . . . . . . . . . . . . 70
DISC BRAKES (REAR). . . . . . . . . . . . . . . . . . . . . 70
DRUM BRAKES (REAR). . . . . . . . . . . . . . . . . . . . 70
BRAKE TUBES AND HOSES . . . . . . . . . . . . . . . . 71

ADJUSTMENTS

DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 71
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . 72
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 72

SPECIFICATIONS

BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
BRAKE ACTUATING SYSTEM . . . . . . . . . . . . . . . 73
BRAKE FASTENER TORQUE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 73

SPECIAL TOOLS

BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 74

BRAKES

5 - 1

DESCRIPTION AND OPERATION

BASE BRAKE SYSTEM

DESCRIPTION

The base brake system consists of the following

components:

• Brake pedal

• power brake booster

• brake tubes and hoses

• proportioning valves

• disc brakes

• drum brakes

• brake lamp switch

• brake fluid level switch

• parking brakes
Front disc brakes control the braking of the front

wheels; rear braking is controlled by rear drum
brakes as standard equipment. Rear disc brakes are
optional.

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.

Vehicles equipped with the optional antilock brake

system (ABS) use a system designated Mark 20i.
This system shares most base brake hardware used
on vehicles without ABS. A vehicle equipped with
ABS, however, uses a different power brake booster,
master cylinder, and brake tubes. Also included in
the ABS system is an integrated control unit (ICU),
four wheel speed sensors, and an electronic controller
referred to as the controller antilock brake (CAB).
These components are described in detail in the
ANTILOCK BRAKE SYSTEM section in this group
of the service manual.

OPERATION

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 chassis brake tubes
and proportioning valves to the brakes at each tire
and wheel assembly.

The

parking

brake

hand-operated.

When

applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel.

BRAKE PEDAL

DESCRIPTION

A suspended type brake pedal is used on this vehi-

cle (Fig. 1). The pedal pivots on a shaft mounted in
the pedal support bracket under the instrument
panel. The pedal also connects to the power brake
booster input rod.

OPERATION

When the brake pedal is depressed, it pushes in on

the power brake booster input rod applying the
brakes. At the same time, it allows the brake lamp
switch’s plunger to extend, thus applying the brake
lamps.

MASTER CYLINDER

DESCRIPTION

This vehicle uses 2 differently designed master cyl-

inder assemblies depending on whether the vehicle is
or is not equipped with antilock brakes.

Vehicles not equipped with ABS use a standard

compensating port master cylinder design, while
vehicles equipped with ABS use a center valve design
master cylinder.

On vehicles equipped with ABS brakes, the master

cylinder is a two outlet design. On vehicles not
equipped with ABS brakes, the master cylinder is a 4
outlet design. All vehicles are equipped with a mas-
ter cylinder having a bore diameter of 22.2 mm.

Fig. 1 Brake Pedal

1 – BUSHINGS
2 – BRAKE PEDAL
3 – BRAKE LAMP SWITCH
4 – PIVOT SHAFT

5 - 2

BRAKES

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