2003 Chrysler PT Cruiser Brake Service (ONLINE REPAIR MANUALS)

Removal

Front

• Depress brake pedal past its first one inch of travel, then hold in this position using suitable holding tool.
• Raise and support vehicle, then remove tire and wheel assembly.
• Remove banjo bolt connecting brake hose to caliper. Discard washers.
• Remove two brake caliper guide pin bolts, then remove caliper from adapter.

Rear

• Depress brake pedal past its first one inch of travel, then hold in this position using suitable holding tool.
• Raise and support vehicle, then remove tire and wheel assembly.
• Remove banjo bolt connecting brake hose to caliper. Discard washers.
• Remove calip...

Brake Lines & Linings

Remove one of the front wheels and inspect the brake disc, caliper and linings.

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective pad is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation o...

Height Sensing Proportioning Valve

1999-2000

• Raise and support vehicle, allowing rear suspension to hang free.
• Remove rear wheel and tire assemblies.
• Support rear axle.
• Disconnect track bar from rear axle, then the shock absorbers.
• Loosen, but do not remove, both leaf spring to front spring hanger pivot bolts.
• Loosen adjustment nut on actuator,. Fig. .
• Ensure hooked end of actuator is properly seated in clip on valve lever and clip is properly positioned on lever of valve.
• Pull housing of valve actuator toward spring hanger until lever on valve bottoms on body of valve. Hold valve actuator i...

Removal

Front

• Raise and support vehicle, then remove tire and wheel assembly.
• Remove two brake caliper guide pin bolts.
• Remove disc brake caliper from disc brake adapter.. Support caliper to prevent brake hose damage.
• Remove brake pads from disc brake caliper adapter.

Rear

• Raise and support vehicle, then remove tire and wheel assembly.
• Remove two caliper guide pin bolts.
• Remove caliper assembly from brake adapter by rotating top of caliper away from rotor, then lifting off machined abutment on adapter,. Fig. . Support caliper to prevent brake hose damage.
• Remove outboard brake shoe from...

Master Cylinder/Power Booster Test

• Start engine and inspect booster vacuum hose connections for leaks.
• Stop engine and shift transmission into neutral.
• Pump brake pedal until all vacuum reserve in booster is depleted.
• Press and hold brake pedal under light foot pressure. Pedal should hold firm. If it falls away master cylinder is faulty.
• Start engine and note pedal action. Pedal should fall away slightly under light foot pressure, then hold firm.
• If no pedal action is felt, the power booster, vacuum supply or vacuum check valve are faulty. Proceed to. "Power Booster Vacuum Test."
• If ...

When wheel slip is detected during a brake application, the ABS enters anti-lock mode. During anti-lock braking, hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold, or increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase hydraulic pressure above the amount which is transmitted by the master cylinder during braking.

During anti-lock braking, a series of rapid pulsations is felt in the brake pedal...