Content .. 446 447 448 449 ..

Chrysler Pacifica. Manual - part 448

(4) After 4 to 8 ounces of brake fluid has been bled

through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate a
good

bleed

the

hydraulic

system

has

been

obtained.

(5) Repeat the procedure at all the other remain-

ing bleeder screws.

(6) Check pedal travel. If pedal travel is excessive

or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.

(7) Perform a final adjustment of the rear brake

shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.

SPECIFICATIONS

BRAKE FASTENER TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

ABS ICU Mounting Bolts To
Bracket

—

ABS ICU Mounting
Bracket-To-Cradle Bolts

250

ABS ICU Mounting
Bracket-To-Frame Bolts

216

ABS ABM-To-HCU Mounting
Screws

—

ABS CAB-To-HCU Mounting
Screws

—

ABS Wheel Speed Sensor
Head Mounting Bolt

180

Adjustable Pedal Position
Sensor Mounting Screws

7.5

—

Adjustable Pedal Mounting
Nuts

250

Brake Tube Nuts

—

120

Brake Hose Bracket Bolt

—

160

Brake Hose Caliper Banjo
Bolt

—

Disc Brake Caliper Adapter
Mounting Bolts - Front

169

125

—

Disc Brake Caliper Adapter
Mounting Bolts - Rear

115

—

Disc Brake Caliper Guide
Pin Bolts - Front

—

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Disc Brake Caliper Guide
Pin Bolts - Rear

200

Disc Brake Caliper Bleeder
Screw

125

Master Cylinder Mounting
Nuts

225

Power Brake Booster
Mounting Nuts

250

Parking Brake Cable
Knuckle Mounting Bolt

250

Parking Brake Front Cable
Guide Mounting Screw

150

Parking Brake Lever (Pedal)
Mounting Bolts And Nut

250

Wheel Mounting (Lug) Nuts

135

100

—

SPECIAL TOOLS

BASE BRAKE SYSTEM

Tubes, Master Cylinder Bleed 8358

Adapter, Master Cylinder Pressure Bleed Cap 6921

BRAKES - BASE

5 - 7

BRAKES - BASE (Continued)

BRAKE FLUID LEVEL SWITCH

REMOVAL

(1) Remove wiring harness connector from brake

fluid reservoir level switch (Fig. 3).

(2) Using fingers, compress the retaining tabs on

the opposite end of brake fluid level switch.

(3) With retaining tabs compressed, grasp the con-

nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.

INSTALLATION

(1) Insert brake fluid level switch into left side of

brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.

(2) Connect vehicle wiring harness connector to

brake fluid level switch (Fig. 3).

Installer, Dust Boot 9089

Dial Indicator, C-3339

Gauge, Brake Shoe C-3919

Handle, Universal C–4171

Installer L-4410

Fig. 3 Brake Fluid Level Switch Connector

1 - MASTER CYLINDER RESERVOIR
2 - WIRING CONNECTOR
3 - ABS ICU
4 - BRAKE FLUID LEVEL SWITCH

5 - 8

BRAKES - BASE

BRAKES - BASE (Continued)

PEDAL POSITION SENSOR -
BRAKE

REMOVAL

(1) Remove battery ground (-) cable from battery

negative post and isolate.

(2) Remove two mounting screws securing pedal

position sensor in place (Fig. 4).

(3) Remove pedal position sensor from pedals

bracket.

(4) Disconnect wiring connector and remove pedal

position sensor.

INSTALLATION

(1) Connect wiring connector to brake pedal posi-

tion sensor.

NOTE: Make sure pin in pedal assembly fits into
slot in sensor carriage when installing sensor.

(2) Place sensor against mounting bracket and into

brake pedal (Fig. 4). Move carriage as necessary to
align slot with pin. Install two mounting screws.
Tighten screws to 7.5 N·m (66 in. lbs.) torque.

(3) Connect ground (-) cable to negative post of

battery.

BRAKE LINES

DESCRIPTION

The brake tubes are steel with a corrosion-resis-

tant nylon coating applied to the external surfaces.

The flex hoses used at each wheel brake are made

of reinforced rubber with fittings at each end. The
fitting at each brake caliper is the banjo-type and
requires a special banjo bolt and copper washers.

OPERATION - BRAKE TUBES AND HOSES

The purpose of the chassis brake tubes and flex

hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle’s suspension.

INSPECTION

Brake tubing should be inspected periodically for

evidence of physical damage or contact with moving
or hot components.

Flexible rubber hose is used at both the front and

rear wheel brakes. Inspection of the flexible brake
hoses should be performed whenever the brake sys-
tem is serviced and every 7,500 miles or 12 months,
whichever comes first. Inspect hydraulic brake hoses
for surface cracking, scuffing, or worn spots. If the
fabric casing of the hose becomes exposed due to
cracks or abrasions in the hose cover, the hose should
be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure.
Faulty installation can cause twisting, resulting in
wheel, tire, or chassis interference.

BRAKE PADS/SHOES - FRONT

REMOVAL

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

(1) Remove master cylinder fluid reservoir cap.
(2) Raise and support vehicle. (Refer to LUBRICA-

TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)

NOTE: Perform Step 3 through Step 9 on each side
of vehicle.

(3) Remove tire and wheel assembly.
(4) Place an appropriately sized C-Clamp over

brake caliper as shown (Fig. 5), placing screw-drive
head against outboard shoe and hook against rear of
caliper. Slowly tighten screw-drive retracting caliper
pistons into bores and breaking outboard brake shoe

Fig. 4 Brake Pedal Position Sensor

1 - WIRING CONNECTOR
2 - BRAKE PEDAL POSITION SENSOR
3 - BRAKE PEDAL
4 - STEERING INTERMEDIATE SHAFT

BRAKES - BASE

5 - 9

free from caliper fingers. Do not overtighten
C-Clamp. 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 though center

opening in top of caliper behind inboard brake shoe
between two caliper pistons. Use care not to come
in contact with pistons or dust boots poten-
tially damaging them. Pry against rear of inboard
brake shoe breaking it free from caliper pistons.

(7) Remove two brake caliper guide pin bolts (Fig.

6).

(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 (Fig. 7).

(10) Install master cylinder fluid reservoir cap.

INSTALLATION

NOTE: Perform Step 1 through Step 6 on each side
of vehicle.

(1) Place

brake

shoes

anti-rattle

clips

adapter (Fig. 7). Make sure clips are properly
installed (Fig. 8).

(2) If applied, remove protective paper from noise

suppression gasket on rear of both inner and outer
brake shoes.

(3) Completely retract caliper piston back into bore

of caliper.

CAUTION: Use care when installing caliper onto
disc brake adapter to avoid damaging boots on cal-
iper guide pins.

(4) Install disc brake caliper over brake shoes on

brake caliper adapter.

Fig. 5 C-Clamp On Caliper

Fig. 6 Front Caliper And Adapter Mounting

1 - CALIPER GUIDE PIN BOLTS
2 - BLEEDER SCREW
3 - BRAKE HOSE BANJO BOLT
4 - CALIPER ADAPTER MOUNTING BOLTS

Fig. 7 Front Brake Shoes Installed

1 - CALIPER GUIDE PINS AND BOOTS
2 - ANTI-RATTLE CLIPS
3 - BRAKE ROTOR
4 - OUTBOARD SHOE (PAD) WITH AUDIBLE WEAR INDICATOR
5 - CALIPER ADAPTER
6 - INBOARD BRAKE SHOE (PAD)

5 - 10

BRAKES - BASE

BRAKE PADS/SHOES - FRONT (Continued)

Content .. 446 447 448 449 ..