Chrysler PT Cruiser. Manual - part 429

(12) Remove the four brake support plate mount-

ing bolts and washers. Separate the brake support
plate from the spindle.

(13) Remove the brake wheel cylinder attaching

bolts (Fig. 131).

(14) Remove the brake wheel cylinder from the

brake support plate.

INSTALLATION

NOTE: When installing wheel cylinder on brake sup-
port plate, be sure it is positioned squarely (hori-
zontal) to the brake support plate.

(1) Install the wheel cylinder onto brake support

plate (Fig. 131). Install and tighten the mounting
bolts to a torque of 13 N·m (115 in. lbs.).

NOTE: When performing the following step, use
new mounting bolts or clean and apply Mopar

Stud & Bearing Mount Adhesive or equivalent to the
original mounting bolt threads before reuse.

(2) Install the brake support plate and seal on

spindle. Tighten the support plate mounting bolts to
a torque of 95 N·m (70 ft. lbs.).

(3) Insert the parking brake cable into its mount-

ing hole in the brake support plate. Push the cable
housing in until the retainer’s fingers lock into place.

(4) Hand start the brake tube nut to the wheel cyl-

inder (Fig. 131). Tighten the tube nut to a torque of
17 N·m (145 in. lbs.).

(5) Non-ABS equipped vehicle only – Attach the

parking brake cable to the parking brake actuator.

(6) Install the rear brake shoe assemblies on the

brake support plate. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE

PADS/SHOES

INSTALLATION)

(7) Install the rear hub and bearing assembly on

the spindle. Install a NEW hub and bearing retain-
ing nut (Fig. 132). Tighten the retaining nut to a
torque of 217 N·m (160 ft. lbs.). Install dust cap.

(8) If equipped with ABS, Install the wheel speed

sensor head into the rear of the support plate (Fig.
130). Install and tighten the sensor mounting bolt to
a torque of 12 N·m (105 in. lbs.).

(9) Adjust the brake shoes to the drum diameter

using a brake shoe gauge. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE

PADS/SHOES

ADJUSTMENT)

(10) Install the brake drum (Fig. 132).
(11) Install the wheel and tire assembly. Tighten

the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).

(12) Lower the vehicle.
(13) Remove the brake pedal holding tool.

(14) Bleed the affected wheel cylinder as neces-

sary. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)

(15) Road test the vehicle to ensure proper brake

operation.

WHEEL CYLINDER - DRUM
BRAKE

REMOVAL

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).

(1) Using a brake pedal holder, depress the brake

pedal past its first one inch of travel and hold it in
this position (Fig. 129). This will isolate the master
cylinder from the brake hydraulic system and will
not allow the brake fluid to drain out of the master
cylinder reservoir.

(2) Raise

and

support

the

vehicle.

(Refer

LUBRICATION

MAINTENANCE/HOISTING

STANDARD PROCEDURE)

(3) Remove the rear tire and wheel assembly.
(4) Disconnect the rear brake tube from the wheel

cylinder (Fig. 131).

(5) Remove

the

brake

drum.

(Refer

BRAKES/HYDRAULIC/MECHANICAL/DRUM

REMOVAL)

(6) Remove the brake shoes from the brake sup-

port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL)

NOTE: If the brake shoes are wet with grease or
brake fluid, replace them.

(7) Remove the brake wheel cylinder mounting

bolts (Fig. 131).

(8) Remove the brake wheel cylinder from the

brake support plate.

(9) If applied, remove old sealer from mounting

surfaces.

INSPECTION

With the brake drums removed, inspect the wheel

cylinder boots for evidence of a brake fluid leak.
Visually check the boots for cuts, tears, or heat
cracks. If any of these conditions exist, the wheel cyl-
inders should be completely cleaned, inspected and
new parts installed.

If a wheel cylinder is leaking and the brake lining

material is saturated with brake fluid, the brake
shoes must be replaced.

5 - 68

BRAKES - BASE

SUPPORT PLATE - DRUM BRAKES (Continued)

INSTALLATION

NOTE: When installing wheel cylinder on brake sup-
port plate, be sure it is positioned squarely (hori-
zontal) to the brake assembly.

(1) Install the wheel cylinder onto the brake sup-

port plate (Fig. 131). Install and tighten the mount-
ing bolts to a torque of 13 N·m (115 in. lbs.).

(2) Hand start the rear brake tube nut to the

wheel cylinder. Tighten the tube nut to a torque of 17
N·m (145 in. lbs.).

(3) Install the rear brake shoes on the brake sup-

port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE

PADS/SHOES

INSTALLATION)

(4) Adjust the rear brakes. (Refer to 5 - BRAKES/

HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- ADJUSTMENTS)

(5) Install the brake drum onto the rear hub.

(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DRUM - INSTALLATION)

(6) Install the tire and wheel assembly. Progres-

sively tighten the wheel mounting nuts to a torque of
135 N·m (100 ft. lbs.).

(7) Lower the vehicle.
(8) Remove the brake pedal holder.
(9) Bleed the wheel cylinder as necessary. (Refer to

5 - BRAKES - STANDARD PROCEDURE)

(10) Road test the vehicle to make sure the brakes

operate correctly.

PARKING BRAKE

DESCRIPTION

The parking brakes consist of the following compo-

nents:

• Hand-operated park brake lever - automatic-ad-

justing

• Parking brake cables (2)

• Actuation levers and struts

• Duo-servo parking brake assembly (rear disc

only)

All vehicles are equipped with a center-mounted,

hand-operated parking brake lever mounted between
the front seats (Fig. 134). This lever is an automatic-
adjusting type that continuously applies minimal
tension to the parking brake cables to keep them in
adjustment at all times.

The parking brake lever has a short output cable

with an equalizer bracket attached to it that connects
to the parking brake cables (Fig. 134). The output
cable can only be serviced as part of the parking
brake lever.

There is an individual parking brake cable for each

rear wheel that joins a parking brake cable equalizer,
attached to the parking brake lever, to the rear park-
ing brakes. The parking brake cables are made of
flexible steel cable. Both drum rear brakes and disc
rear brakes use the same parking brake cable config-
uration, but the cables are different.

On vehicles equipped with rear drum brakes, the

rear wheel service brakes also act as the vehicle’s
parking brakes. The rear drum brake shoes, when
acting as parking brakes, are mechanically operated
using an internal actuating lever and strut connected
to the flexible steel parking brake cable.

The parking brakes on vehicles equipped with rear

disc brakes consist of a small duo-servo brake assem-
bly mounted to the disc brake caliper adapter (Fig.
135). The hat (center) section of the rear brake rotor
serves as the braking surface (drum) for the parking
brakes (Fig. 136). This parking brake application
uses the same operating cable configuration as the
drum brake equipped vehicles, but different cables.

OPERATION

When the parking brake is applied, the equalizer

bracket on the lever output cable pulls on both parking
brake cables, thus applying the brake shoes (rear drum
brakes) or parking brake shoes (rear disc brakes).

The brake shoes are mechanically operated by an

internal lever and strut connected to the parking
brake cables.

The parking brake lever automatic-adjusting feature

continuously applies minimal tension to the parking
brake cables to keep them in adjustment at all times.
Therefore, the parking brake cable system does not
require adjustment. Proper parking brake system
adjustment is obtained by proper drum brake or drum-
in-hat brake shoe adjustment. When service is needed,
the lever auto-adjust mechanism must be reloaded and
locked out before service can be performed.

Fig. 134 Parking Brake Lever

1 - OUTPUT CABLE
2 - SWITCH

BRAKES - BASE

5 - 69

WHEEL CYLINDER - DRUM BRAKE (Continued)

STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER LOCKOUT

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCKSPRING LOADED TO APPROXIMATELY 19
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.

WARNING:

WHEN

REPAIRS

THE

PARKING

BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY.

LOCKING AUTOMATIC ADJUSTER OUT

(1) Block the tire and wheels so the vehicle does

not move once the vehicle parking brake lever is
released.

(2) Remove the transmission shift knob as neces-

sary.

(3) Place parking brake lever in released (full

OFF) position.

(4) Remove the screws attaching the center con-

sole.

(5) Remove rear window switch panel from the

console.

(6) Working through switch opening, grasp a park-

ing brake cable or equalizer and pull back approxi-
mately 25.4 mm (1 in.)

(7) While holding the cable or equalizer, pull the

parking brake handle to it’s full upright position.

(8) Remove center console.
(9) Grasp the parking brake lever output cable by

hand and pull upward. Continue pulling cable until
an appropriate pin punch (drill bit or locking pin) can
be inserted sufficiently through hole in left side of
the lever mounting bracket (Fig. 137). This will lock
the parking brake automatic adjustment mechanism
in place and take tension off the parking brake
cables. Slowly release the output cable. There should
now be slack in the cables.

Fig. 135 Parking Brake Assembly With Rear Disc

Brakes

1 - DISC BRAKE ADAPTER
2 - PARKING BRAKE BRAKE SHOES
3 - HUB/BEARING ASSEMBLY
4 - BRAKING DISC STONE SHIELD
5 - PARKING BRAKE ACTUATING STRUT

Fig. 136 Drum-In-Hat Brake Rotor

1 - REAR BRAKE ROTOR
2 - HAT SECTION OF ROTOR (PARKING BRAKE BRAKING
SURFACE)

5 - 70

BRAKES - BASE

PARKING BRAKE (Continued)

UNLOCKING AUTOMATIC ADJUSTER (UNLOADING)

(1) Be sure the rear parking brake cables are both

properly installed in the equalizer.

(2) Raise parking brake handle to the full upright

position.

(3) Keeping your hands clear of the automatic

adjuster sector and pawl area, firmly grasp the park-
ing brake lever pin punch (drill bit or locking pin if a
new mechanism has been installed) (Fig. 137), then
quickly remove it from the parking brake lever mech-
anism. This will allow the park brake lever mecha-
nism to automatically adjust the parking brake
cables.

(4) Install the center console and its mounting

screws.

(5) Cycle the parking brake lever once to position

the parking brake cables, then return the parking
brake lever to its released (full OFF) position.

(6) Check the rear wheels of the vehicle. They

should rotate freely without dragging with the lever
in its released (full OFF) position.

(7) Install rear window switch panel.
(8) Remove the blocks from the tire and wheels.

CABLE - PARKING BRAKE

REMOVAL

WARNING: THE AUTOMATIC ADJUSTING FEATURE
OF THIS PARKING BRAKE LEVER CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 19
POUNDS. DO NOT RELEASE THE AUTOMATIC
ADJUSTER LOCKOUT DEVICE UNLESS THE REAR
PARKING BRAKE CABLES AND EQUALIZER ARE
CONNECTED TO THE LEVER OUTPUT CABLE.
KEEP HANDS OUT OF AUTOMATIC ADJUSTER
SECTOR AND PAWL AREA. FAILURE TO OBSERVE
CAUTION IN HANDLING THIS MECHANISM COULD
LEAD TO SERIOUS INJURY.

WARNING:

WHEN

REPAIRS

THE

PARKING

BRAKE LEVER OR CABLES ARE REQUIRED, THE
AUTOMATIC ADJUSTER MUST BE LOADED AND
LOCKED OUT TO AVOID POSSIBLE INJURY. THE
LEVER

ADJUSTMENT

MECHANISM

CAN

LOADED AND LOCKED OUT AS OUTLINED IN THIS
PROCEDURE.

WARNING: THE AIRBAG SYSTEM IS A COMPLEX
ELECTROMECHANICAL UNIT. BEFORE ATTEMPT-
ING TO SERVICE ANY COMPONENT NEAR THE
OCCUPANT

RESTRAINT

CONTROLLER

(ORC),

FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE CABLE. ALLOW THE SYSTEM CAPACI-
TOR TO DISCHARGE FOR TWO (2) MINUTES. FAIL-
URE TO DO THIS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).

NOTE: The procedure below applies to either of the
two rear parking brake cables.

Fig. 137 Pin Punch Installed

1 - PARKING BRAKE LEVER
2 - OUTPUT CABLE
3 - PIN PUNCH

BRAKES - BASE

5 - 71

PARKING BRAKE (Continued)

Content .. 427 428 429 430 ..