Index Chrysler Chrysler Crossfire - service repair manual 2005 year

Content .. 40 41 42 43 ..

Chrysler Crossfire. Manual - part 42

BRAKES

TABLE OF CONTENTS

page

page

BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRAKES - ABS ELECTRICAL DIAGNOSTICS . . . . 87

BRAKES - ABS SERVICE INFORMATION . . . . . . 244

BRAKES - BASE

TABLE OF CONTENTS

page

page

BRAKES - BASE

. . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSIS AND TESTING - BASE BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

STANDARD PROCEDURE

STANDARD PROCEDURE - MANUAL

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

STANDARD PROCEDURE - PRESSURE

BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BRAKE COMPONENTS

. . . . . . . . . . . . . . . . . 10

BRAKE LINES

. . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSIS AND TESTING - BRAKE HOSES

. . . . . . . . . . . . . . . . . . . . . . . . . . 12

STANDARD PROCEDURE

STANDARD PROCEDURE - DOUBLE

INVERTED FLARING . . . . . . . . . . . . . . . . . . . 12

STANDARD PROCEDURE - ISO FLARING

FRONT BRAKE HOSE

. . . . . . . . . . . . . . . . . . 14

REAR BRAKE HOSE

. . . . . . . . . . . . . . . . . . . 15

FRONT BRAKE HOSE

. . . . . . . . . . . . . . . . . . 16

INSTALLATION - REAR BRAKE HOSE

BRAKE PADS/SHOES

FRONT DISC BRAKE PADS

. . . . . . . . . . . . . . 18

REMOVAL - REAR DISC BRAKE PADS

FRONT DISC BRAKE PADS

. . . . . . . . . . . . . . 22

INSTALLATION - REAR DISC BRAKE PADS

DISC BRAKE CALIPERS

. . . . . . . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FRONT DISC BRAKE CALIPER

. . . . . . . . . . . 26

REMOVAL - REAR BRAKE CALIPER

. . . . . . . 29

DISASSEMBLY - FRONT DISC BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

CLEANING - DISC BRAKE CALIPER

. . . . . . . . . 31

INSPECTION - DISC BRAKE CALIPER

. . . . . . . 31

ASSEMBLY - FRONT DISC BRAKE CALIPER

FRONT DISC BRAKE CALIPER

. . . . . . . . . . . 32

INSTALLATION - REAR DISC BRAKE

CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

ROTORS

DIAGNOSIS AND TESTING

DISC BRAKE ROTORS

. . . . . . . . . . . . . . . . . 37

STANDARD PROCEDURE

DISC BRAKE ROTOR MACHINING

. . . . . . . . 39

FRONT DISC BRAKE ROTOR

. . . . . . . . . . . . 39

REMOVAL - REAR DISC BRAKE ROTOR

FRONT DISC BRAKE ROTOR

. . . . . . . . . . . . 41

INSTALLATION - REAR DISC BRAKE

ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FLUID

DIAGNOSIS AND TESTING

BRAKE FLUID CONTAMINATION

. . . . . . . . . . 43

STANDARD PROCEDURE

MASTER CYLINDER FLUID LEVEL

. . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . 44

MASTER CYLINDER

MASTER CYLINDER

. . . . . . . . . . . . . . . . . . . 45

MASTER CYLINDER

. . . . . . . . . . . . . . . . . . . 45

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BRAKES

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DIAGNOSIS AND TESTING

MASTER CYLINDER/POWER BOOSTER

DIAGNOSIS AND TESTING - MASTER

CYLINDER FLUID LOSS . . . . . . . . . . . . . . . . 46

STANDARD PROCEDURE

MASTER CYLINDER BLEEDING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

. . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . 50

INSTALLATION - RHD

. . . . . . . . . . . . . . . . . . 51

POWER BRAKE BOOSTER

. . . . . . . . . . . . . . . . . . . . . . . . . 52

. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . 57

INSTALLATION - RHD

. . . . . . . . . . . . . . . . . . 58

PEDAL

. . . . . . . . . . . . . . . . . . . . . . . . . 60

. . . . . . . . . . . . . . . . . . . . . . . . . . . 60

. . . . . . . . . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . 62

. . . . . . . . . . . . . . . . . . . . . . . 64

INSTALLATION - RHD

. . . . . . . . . . . . . . . . . . 65

PARKING BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

DIAGNOSIS AND TESTING

. . . . . . . . . . . . . . . . . . . . . 68

. . . . . . . . . . . . . . . . . . . . . . . . 69

CABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

. . . . . . . . . . . . . . . . . . . . . . . . . 73

LEVER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

. . . . . . . . . . . . . . . . . . . . . . . . . 77

SHOES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

. . . . . . . . . . . . . . . . . . . . . . . . . 81

BRAKE FLUID LEVEL SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

. . . . . . . . . . . . . . . . . . . . . . . . . 84

BRAKE PRESSURE SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

. . . . . . . . . . . . . . . . . . . . . . . . . 85

TRAVEL SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

. . . . . . . . . . . . . . . . . . . . . . . . . 86

5 - 2

BRAKES - BASE

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BRAKES - BASE

DESCRIPTION

Power brake assist is supplied by a vacuum operated, power brake booster.

1 - BAS BRAKE BOOSTER
2 - BAS SOLENOID VALVE
3 - AIR FILTER
4 - AIR FILTER
5 - POPPET VALVE
6 - BAS RELEASE SWITCH
7 - VACUUM PISTON

8 - BAS DIAPHRAGM TRAVEL SENSOR
9 - COMPRESSION SPRING
10 - OUTPUT ROD
11 - CABLE CONNECTOR FOR RELEASE SWITCH AND
SOLENOID VALVE
12 - VACUUM CONNECTION
13 - POWER DIAPHRAGM

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BRAKES - BASE

5 - 3

Single piston brake calipers (3) are used on the front
and on the rear. Ventilated disc brake rotors (2) are
used on the front and solid disc brake rotors are used
on the rear.

The master cylinder has an aluminum body and a
nylon reservoir with a single filler cap. A fluid level
indicator (2) is molded into the top of the reservoir.
The fill levels (1) are located on the side.

Factory installed brake linings consist of organic base
material combined with metallic particles.

WARNING

WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN
ASBESTOS FIBERS FROM AFTERMARKET LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF
ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. USE A VACUUM
CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF ASBESTOS FIBERS FROM BRAKE COMPO-
NENTS. IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS
DESIGNED TO CONTAIN THE DUST RESIDUE. DISPOSE OF ALL RESIDUE CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS TO MINIMIZE EXPOSURE TO YOURSELF AND OTHERS. FOLLOW
PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION AND THE
ENVIRONMENTAL PROTECTION AGENCY FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST
OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS.

5 - 4

BRAKES - BASE

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