1995 Dodge Caravan Brake Service (ONLINE REPAIR MANUALS)

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 ...

Excessive Pedal Travel

• Worn brake lining.
• Pad knock back after cornering or rough road travel.
• Piston or pad assembly not properly seated or positioned.
• Air leak or insufficient fluid in system or caliper.
• Loose wheel bearing adjustment.
• Damaged or worn caliper piston seal.
• Improper booster pushrod adjustment.
• Pads out of flat more than .005 inch.
• Rear brake automatic adjusters inoperative.
• Improperly ground rear brake shoe and lining assemblies.

Brake Roughness Or Chatter; Pedal Pumping

• Excessive lateral runout of rotor.
• Rotor excessively out of parallel.

Excessive Pedal Effort

• Frozen or seiz...

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...

Accessing Diagnostic Trouble Codes

The diagnostic connector, Figs. and , is located under the lefthand side of the instrument panel. On 1992-94 models, it is a blue 6-way connector; on 1995 models, it is a black 8-way connector. 1996 models utilize a 16-way connector which also serves as a diagnostic link for the PCM and air bag electronic control module. In all cases, a DRB diagnostic scan tool can be linked to this connector to obtain diagnostic trouble codes.

1992-93

• Connect DRB scan tool to diagnostic connector.
• Turn ignition switch to On position. Do not touch keypad durin...

Brake Drums

Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor scor...

General Service Precautions

Certain components of the anti-lock brake system are not intended to be serviced individually. Attempting to remove or disconnect components of this type may result in personal injury and/or improper system operation. Only the components with removal and installation procedures should be serviced.

Observe the following general precautions when servicing the anti-lock brake system:

• If any welding work is to be performed using an arc welder, Controller Anti-Lock Brake (CAB) should be disconnected.
• When ignition switch is in On position, CAB electrical connector...