1996 Dodge B2500 VAN Brake Service (ONLINE REPAIR MANUALS)

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...

Brake Shoe, Replace

Prior to removing brake shoes it is recommended that a suitable clip or restraining device be applied to the wheel cylinders to prevent wheel cylinder pistons from being pushed out of their bores.

Do not intermix automatic adjuster components from side to side.

Models w/ 9, 10, 11 & 13 Inch Drums

1992-93 Full Size Pickup & 1992-95 Caravan, Town & Country & Voyager

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Remove brake drum, noting the following:
• If brake lining is dragging on brake drum, lift auto adjuster lever off star wheel, the...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level due to a chemical breakdown during use, and a few precautions will minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.

• Wear a s...

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...

These self contained vacuum hydraulic power braking units are of the vacuum suspended type. They use engine intake manifold vacuum or a vacuum pump, along with atmospheric pressure, for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, with integral vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied t...

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...