1992 Dodge Grand Caravan Brake Service (ONLINE REPAIR MANUALS)

Chrysler

Except Caravan, Town & Country & Voyager

Manual Bleeding

• On models equipped with Rear Wheel Anti-Lock brakes (RWAL), connect one end of a suitable hose to bleeder valve on RWAL hydraulic valve and submerge other end in a glass container partially filled with clean brake fluid.
• Pump brake pedal several times, then hold pedal down firmly.
• With pedal firmly depressed, open bleeder valve until pedal fades to floor, then close bleeder valve.
• Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. Ensure a fluid level is maintained in master cylin...

Chrysler

Proportioning Valve

Caravan, Town & Country & Voyager

• Lift vehicle with a frame contact hoist or other means so that rear suspension is hanging free with shock absorbers disconnected. Remove tire and wheel assemblies from rear axle.
• After installing a new height sensing proportioning valve, bleed both hydraulic circuits at rear brakes.
• Reinstall rubber stone shield and ensure rear springs do not contact hoist, then loosen both front spring hanger pivot bolts.
• Loosen adjustment nut on actuator assembly, Fig. , then check actuator assembly hook. The hook should be properly seated o...

Master Cylinder

Chrysler

Caravan, Town & Country & Voyager

1992-95

• Disconnect and plug brake tubes from master cylinder. Cap master cylinder ports.
• Remove master cylinder attaching nuts.
• Remove master cylinder from power brake unit.
• Reverse procedure to install. Master cylinder should be bench bled before installation, using bleeding tubes tool No. C-4546, or equivalent.

1996

• With engine not running, pump brake pedal four or five times to deplete vacuum in power booster.
• Thoroughly clean all surfaces of filler neck, brake fluid reservoir and area where master cylinder assembly attac...

Master Cylinder

Front & Rear Split Systems

When the brake pedal is depressed, both the primary (front brake) and the secondary (rear brake) master cylinder pistons are moved simultaneously to exert hydraulic fluid pressure on their respective independent hydraulic systems. The fluid displacement of the two master cylinders is proportioned to fulfill the requirements of each of the two independent hydraulic brake systems.

If a failure of the rear (secondary) brake system should occur, initial brake pedal movement causes the unrestricted secondary piston to bottom in the master cylinder ...

Chrysler

Proportioning Valve

Caravan, Town & Country & Voyager

These models use a proportioning valve and pressure differential switch, or a combination valve. When a premature rear wheel skid is obtained during braking, it may be an indication that fluid pressure to rear brakes is above a desired output and/or a malfunction has occurred within the valve. At this time, the valve unit should be tested as follows:

• Remove actuator assembly adjustment nut, Fig. , then disconnect assembly from valve lever and remove.
• Install gauge and Tee from line pressure set No. C-4007, or equivale...

Service Brake

Except FWD Models & Ram 50

Self-Adjusting Brakes

These brakes have self-adjusting shoe mechanisms that ensure correct lining to drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the car is moving rearward.

Although the brakes are self-adjusting, an initial adjustment is necessary when the brake shoes have been relined, replaced or when the length of the star wheel adjuster has been changed during some other service operation.

Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent t...