Chrysler PT Cruiser. Manual - part 413

CAUTION: When handling the brake rotor and cali-
per, 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.

5 - 4

BRAKES - BASE

BRAKES - BASE (Continued)

CONDITION

POSSIBLE CAUSES

CORRECTION

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.

SCRAPING (METAL-TO-
METAL).

1. Foreign object interference with
brakes.

1. Inspect brakes and remove foreign
object.

2. Brake shoes worn out.

2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.

SCRAPING OR WHIRRING

1. ABS wheel speed sensor hitting
tone wheel.

1. Inspect, correct or replace faulty
component(s).

OTHER BRAKE CONDITIONS

CONDITION

POSSIBLE CAUSES

CORRECTION

BRAKES CHATTER

1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.

1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.

BRAKES DRAG (FRONT
OR ALL)

1. Contaminated brake fluid.

1. Check for swollen seals. Replace all
system components containing rubber.

2. Binding caliper pins or bushings.

2. Replace pins and bushings

3. Misadjusted brake lamp switch.

3. Replace brake lamp switch. (Refer to
8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL)

4. Master cylinder not fully returning.

4. Inspect master cylinder and replace
as necessary.

5. Binding brake pedal.

5. Replace brake pedal/bushings.

BRAKES DRAG (REAR
ONLY)

1. Parking brake cables binding or
froze up.

1. Check cable routing. Replace cables
as necessary.

2. Parking brake cable return spring
not returning shoes.

2. Replace cables as necessary.

3. Service brakes not adjusted
properly (rear drum brakes only).

3. Adjust rear brake shoes. Refer to
Brake Pads/Shoes - Drum Brake.

4. Obstruction inside the center
console preventing full return of the
parking brake cables.

4. Remove console and remove
obstruction.

BRAKES GRAB

1. Contaminated brake shoe linings.

1. Inspect and clean, or replace shoes.
Repair source of contamination.

2. Improper power brake booster
assist.

2. Refer to Power Brake Booster in this
section.

BRAKES - BASE

5 - 5

BRAKES - BASE (Continued)

CONDITION

POSSIBLE CAUSES

CORRECTION

EXCESSIVE PEDAL
EFFORT

1. Obstruction of brake pedal.

1. Inspect, remove or move obstruction.

2. Low power brake booster assist.

2. Refer to Power Brake Booster in this
section.

3. Glazed brake linings.

3. Reface or replace brake rotors as
necessary. Replace brake shoes.

4. Brake shoe lining transfer to brake
rotor.

4. Reface or replace brake rotors as
necessary. Replace brake shoes.

EXCESSIVE PEDAL
EFFORT (HARD PEDAL -
CAN’T SKID WHEELS)

1. Power brake booster runout
(vacuum assist).

1. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to Power Brake Booster.

EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)

1. Air in brake lines.

1. Bleed brakes.

2. Rear drum brake auto-adjuster
malfunctioning.

2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.

EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)

1. One of the two hydraulic circuits is
malfunctioning.

1. Inspect system for leaks. Check
master cylinder for internal malfunction.

PEDAL PULSATES/
SURGES DURING
BRAKING

1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.

1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.

PEDAL IS SPONGY

1. Air in brake lines.

1. Bleed brakes.

PREMATURE REAR
WHEEL LOCKUP

1. Contaminated brake shoe linings.

1. Inspect and clean, or replace shoes.
Repair source of contamination.

2. Inoperative proportioning valve
(non-ABS vehicles only).

2. Test proportioning valves following
diagnosis and testing procedure. Refer
to Proportioning Valve. Replace valves
as necessary.

3. ABS EVBP not functioning.

3. Refer to the ABS section and
Appropriate Diagnostic Information.

STOP LAMPS STAY ON

1. Brake lamp switch out of
adjustment.

1. Replace brake lamp switch. (Refer to
8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL)

2. Brake pedal binding.

2. Inspect and replace as necessary.

3. Power brake booster not allowing
pedal to return completely.

3. Replace power brake booster.

5 - 6

BRAKES - BASE

BRAKES - BASE (Continued)

CONDITION

POSSIBLE CAUSES

CORRECTION

VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING

1. Frozen brake caliper piston.

1. Replace frozen piston or caliper.
Bleed brakes.

2. Contaminated brake shoe lining
(most likely front lining).

2. Inspect and clean, or replace shoes.
Repair source of contamination.

3. Pinched brake lines.

3. Replace pinched line.

4. Leaking piston seal.

4. Replace piston seal or brake caliper.

5. Suspension problem.

5. Refer to the Suspension section.

PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL

1. Rear brakes out of adjustment.

1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.

STANDARD PROCEDURE - BASE BRAKE
BLEEDING

NOTE: For bleeding the ABS hydraulic system, refer
to Antilock Brake System Bleeding in the Antilock
Brake System section.

CAUTION: Before removing the master cylinder cap,
wipe it clean to prevent dirt and other foreign mat-
ter from dropping into the master cylinder reservoir.

CAUTION: Use only Mopar

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. 1).

(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).

Fig. 1 Proper Method for Purging Air From Brake

System (Typical)

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

BRAKES - BASE

5 - 7

BRAKES - BASE (Continued)

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