Chrysler PT Cruiser. Manual - part 417

CLEANING - DISC BRAKE SHOES

WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET

BRAKE

LININGS.

BREATHING

EXCESSIVE

CONCENTRATIONS

ASBESTOS

FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE

CARE

WHEN

SERVICING

BRAKE

PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS

WITH

COMPRESSED AIR

BY DRY

BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.

INSPECTION - DISC BRAKE SHOES

Visually inspect brake shoes (pads) for uneven lin-

ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors.

If a visual inspection does not adequately deter-

mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers.

Measure each brake shoe. The combined brake

shoe and its lining material thickness should be mea-
sured at its thinnest point.

• For front disc brake shoes, when a set of brake

shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.

• For rear disc brake shoes, when a set of brake

shoes are worn to a thickness of approximately 9.0
mm (3/8 inch), they should be replaced.

• Typically, if front shoes are worn out, both fronts

and rears need to be replaced. Make sure to check
rears.

Replace both disc brake shoes (inboard and out-

board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.

If the brake shoe assemblies do not require

replacement, be sure to reinstall the brake shoes in
the original position they were remove from.

INSTALLATION

CAUTION: When installing new brake components,
be sure to use correct parts. Parts designed for
BR4 Performance Brake System must not be mixed
with other brake systems. These parts, similar in
appearance, can be easily identified (Fig. 16) (Fig.
17). (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL - DESCRIPTION - DISC BRAKES (REAR))

NOTE: Perform Step 1 through Step 7 on each side
of the vehicle to complete shoe set installation,
then proceed to Step 8.

(1) Completely retract the caliper piston back into

piston bore of the caliper. This is required to gain the
necessary shoe-to-rotor clearance for the caliper
installation onto the steering knuckle.

(2) Install the inboard brake shoe into the caliper

piston by firmly pressing the shoe in with the
thumbs (Fig. 25). Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.

(3) Slide the outboard brake shoe onto the caliper

assembly (Fig. 24). Be sure the retaining clip is
squarely seated in the depressed areas on the caliper.

(4) Lubricate both adapter caliper slide abutments

with a liberal amount of Mopar

t Multipurpose Lubri-

cant, or an equivalent.

CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.

(5) Starting with the lower end, carefully lower the

caliper and brake shoes over the brake rotor and
catch the caliper’s bottom edge behind the caliper
slide abutment (Fig. 22). Rotate the top of the caliper
into mounting position on the adapter.

CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.

(6) Carefully install the caliper guide pin bolts

(Fig. 21), then tighten them to a torque of 22 N·m
(192 in. lbs.).

(7) Install the tire and wheel assembly. Tighten

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

(8) Lower the vehicle.

5 - 20

BRAKES - BASE

BRAKE PADS/SHOES - REAR DISC (Continued)

(9) Pump the brake pedal several times to ensure

the vehicle has a firm brake pedal before moving the
vehicle.

(10) Road test the vehicle and make several stops

to wear off any foreign material on the brakes and to
seat the brake shoes.

BRAKE PADS/SHOES - REAR
DRUM

REMOVAL

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

NOTE: Make sure parking brake is in “released”
position before raising vehicle.

(1) Raise and support vehicle. (Refer to LUBRICA-

TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)

(2) Remove both rear tire and wheel assemblies

from vehicle.

(3) Remove brake drums from both sides of vehicle

(Fig. 26). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DRUM - REMOVAL)

NOTE: Perform Step 4 through Step 12 on each
side of the vehicle to complete shoe set removal. It
may be easier to install the new components on the
first side of the vehicle before disassembling the
opposite side so it may be used as a reference
guide for proper installation. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REAR DRUM - INSTALLATION)

(4) Remove hub and bearing dust cap (Fig. 26).
(5) Remove hub and bearing retaining nut, then

slide hub and bearing off spindle (Fig. 26).

(6) Compress cable return spring, then remove

parking brake cable from parking brake lever (Fig.
27).

(7) Remove lower return spring (Fig. 28).
(8) Compress and remove shoe hold-down spring

clips (Fig. 28).

(9) Remove both shoes and remaining parts as an

assembly from anchor and wheel cylinder (Fig. 28).

Fig. 26 Drum Brakes

1 - DUST CAP
2 - NUT
3 - DRUM
4 - HUB AND BEARING
5 - WHEEL CYLINDER
6 - SUPPORT PLATE
7 - BRAKE SHOES

Fig. 27 Cable Removal From Lever

BRAKES - BASE

5 - 21

BRAKE PADS/SHOES - REAR DISC (Continued)

(10) Remove adjuster spring from leading shoe and

lever pawl (Fig. 29).

(11) Remove lever pawl from pivot on leading shoe

and slide out from under adjuster.

(12) Remove adjuster and upper spring from shoes.

(Fig. 29).

CLEANING

WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET

BRAKE

LININGS.

BREATHING

EXCESSIVE

CONCENTRATIONS

ASBESTOS

FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE

CARE

WHEN

SERVICING

BRAKE

PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS

WITH

COMPRESSED AIR

BY DRY

INSPECTION

Rear brake shoe lining should show contact across

the entire width of the lining and also from the heel
to the toe of the lining. Replace the shoes if noted
otherwise.

Brake shoes with lack of contact at the toe or heel

of the brake shoe lining may be improperly ground.

Clean and inspect the brake support plate and

shoe adjuster screw. Apply a thin coat of Mopar

Multi-Purpose Grease or equivalent to the threads of
the self-adjuster. Replace the adjuster screw if it is
corroded.

NOTE: Adjuster screws are different side-to-side.
Left side adjuster screws have left-hand threads
and right side adjuster screws have right-handed
threads.

If the old brake shoe return or hold down springs

have overheated or are damaged, replace them. Over-
heating indications are paint discoloration or dis-
torted end coils.

Fig. 28 Shoes Mounted To Support Plate

1 - HOLD-DOWN SPRING CLIPS
2 - WHEEL CYLINDER
3 - ANCHOR
4 - LOWER RETURN SPRING

Fig. 29 Bench Assembled Shoes (Right Side Shown)

1 - LEVER
2 - UPPER RETURN SPRING
3 - LEVER PAWL
4 - LEADING SHOE
5 - ADJUSTER SPRING
6 - ADJUSTER
7 - TRAILING SHOE

5 - 22

BRAKES - BASE

BRAKE PADS/SHOES - REAR DRUM (Continued)

INSTALLATION

NOTE: Perform Step 1 through Step 11 on each side
of vehicle to complete shoe set installation, then
proceed to Step 12.

(1) Lubricate six shoe contact areas on support

plate and anchor using Mopar

t Brake Lubricant or

equivalent (Fig. 30).

(2) Before installing shoes on vehicle, perform the

following on the bench:

(a) Place one leading and one trailing shoe on

bench (trailing shoe has parking brake lever
attached to it).

(b) Install adjuster and upper spring (Fig. 29).
(c) Slide lever pawl under adjuster and onto

pivot on leading shoe.

(d) Install adjuster spring between leading shoe

and lever pawl (Fig. 29).
(3) Install pre-assembled brake shoe assembly over

wheel cylinder and anchor on brake support plate
(Fig. 28).

(4) Install both shoe hold-down pins from rear

(Fig. 31), through support plate and shoes.

(5) Compress and install shoe hold-down spring

clips on pins (Fig. 28).

(6) Install lower return spring (Fig. 28).
(7) Compress parking brake cable return spring,

then install cable on parking brake lever (Fig. 32).
Release spring guiding it beneath retaining tab on
lever.

(8) Slide hub and bearing onto spindle (Fig. 26).

Install retaining nut and tighten to 217 N·m (160 ft.
lbs.) torque.

(9) Install hub and bearing dust cap (Fig. 26).
(10) Adjust brake shoes to drum diameter using

brake shoe gauge. (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/BRAKE

PADS/SHOES

ADJUSTMENTS)

(11) Install brake drum (Fig. 26). (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/DRUM

INSTALLATION)

Fig. 30 Shoe Contact Areas on Support Plate

Fig. 31 Rear View Of Brake Support Plate (Right

Side Shown)

1 - WHEEL CYLINDER MOUNTING BOLTS
2 - WHEEL CYLINDER
3 - SHOE HOLD-DOWN PINS
4 - SHOE WEAR INSPECTION HOLE
5 - ADJUSTER ACCESS HOLE

Fig. 32 Cable Installation To Lever

BRAKES - BASE

5 - 23

BRAKE PADS/SHOES - REAR DRUM (Continued)

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