Brake System

1984 Dodge Caravan
BRAKE SYSTEM 1984 BRAKES Chrysler Motors - Brake System
BRAKE SYSTEM
1984 BRAKES Chrysler Motors - Brake System
DESCRIPTION
BRAKE BOOSTER - BENDIX SINGLE DIAPHRAGM
This unit uses engine manifold vacuum and atmospheric pressure to assist braking. Vacuum power unit contains
power piston assembly, which houses control valve, reaction mechanism and return spring.
Control valve consists of air valve, floating control valve assembly, and push rod. Reaction mechanism includes
reaction plate and levers. A vacuum check valve is mounted in front housing for connection to vacuum source.
BRAKE BOOSTER - BENDIX TANDEM DIAPHRAGM
The power brake unit uses engine manifold vacuum and atmospheric pressure to provide power-assisted brake
application.
Vacuum power chamber includes front and rear shell, center plate, tandem front and rear diaphragms (with plate
assembly), hydraulic push rod and vacuum diaphragm, and diaphragm return spring. A mechanically actuated
control valve is integral with diaphragms.
DISC BRAKES
Chrysler vehicles are equipped with single piston, sliding caliper disc brakes. Brake assembly consists of hub
and disc assembly, caliper, disc pads, splash shield (except front wheel drive) and adapter. Cooling fins are cast
integrally between machined braking surfaces.
When the brake pedal is depressed, hydraulic pressure is applied against brake caliper piston. This force is
transmitted to in-board brake pad and inner surface of disc. As force increases against inboard side, caliper
slides inward on machined disc plate ramps, providing vise-like clamping action on disc.
DRUM BRAKES
Chrysler Corp. vehicles use both Chrysler and Bendix single anchor brake assemblies. Chrysler type brake
design is used on all 9" and 11" diameter brake applications. Bendix type brake design is used on all 12" brake
applications.
Both types of brake assemblies consist of a support plate, 2 brake shoes, return springs, wheel cylinder, and a
cable type adjuster assembly. The automatic adjuster assembly consists of a cable (with hook and anchor
fitting), cable guide, adjuster lever, adjusting screw, pivot, socket, and spring.
MASTER CYLINDER - BENDIX/DELCO-MORAINE DUAL PISTON
NOTE: Optional on Dodge W250/350 & D350 only.
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1984 Dodge Caravan
Bendix and Delco-Moraine tandem dual piston master cylinders are single casting type with front and rear
pistons and a separate reservoir and outlet for each piston.
Rear piston is operated by push rod connected to brake pedal. Front piston is operated by rear piston. In a
combination disc and drum system, reservoir which feeds disc brakes is larger to compensate for larger
displacement of disc caliper cylinder.
MASTER CYLINDER - CHRYSLER ALUMINUM DUAL PISTON
The aluminum tandem dual piston master cylinder is of the venting type with nylon reservoir. The front and rear
pistons have separate reservoirs and outlets.
The reservoir may be filled from 1 cap because reservoirs are connected at the top. Air entrapment is controlled
by cup expanders in rear brake wheel cylinders. No residual pressure valves are installed on this master
cylinder.
MASTER CYLINDER - CHRYSLER CAST IRON DUAL PISTON
This tandem dual piston master cylinder is of the venting type, with reservoirs in a single casting and one outlet
for each reservoir. Rear piston is operated by push rod connected to brake pedal. Front piston is operated by rear
piston.
BRAKE SYSTEM BLEEDING

Hydraulic system bleeding is necessary any time air has been introduced into system. Bleed brakes at all four
wheels if master cylinder lines have been disconnected or master cylinder has been run dry. Bleed brakes with
pressure bleeding equipment or by manually pumping brake pedal while using bleeder tubes.
NOTE: Hydro-Boost bleeding is a different procedure than hydraulic brake bleeding.

Refer to HYDRO-BOOST BLEEDING in the HYDRO-BOOST SYSTEM article in
this section.
HYDRAULIC CONTROL VALVES
On disc brake equipped vehicles, metering section of hydraulic control valve must be deactivated before
bleeding to permit fluid to flow to front brakes. This is especially important when pressure bleeding.
Use pressure tool when applicable (C-4121, Chrysler Corp). If tool is not available, hold valve open by hand.
DO NOT use "C" clamp or other non-yielding device to hold valve open.
PRESSURE TANK BLEEDING
1. Clean master cylinder cap and surrounding area. Remove cap. With pressure tank at least 1/2 full, connect
to master cylinder with adapters. Attach bleeder hose to first bleeder valve to be serviced. See
BLEEDING SEQUENCE table.
2. Place other end of hose in clean glass jar partially filled with clean brake fluid so end of hose is
submerged in fluid. Open release valve on pressure bleeder. Follow equipment manufacturers pressure
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1984 Dodge Caravan
instructions unless noted below.

3. Unscrew bleeder valve 3/4-1 turn noting fluid flow. When fluid flowing from cylinder to jar is free of
bubbles, close bleeder valve securely. Bleed remaining cylinders in correct sequence and in the same
manner. Remove tool from control valve.
PRESSURE BLEEDER SETTINGS

Application psi (kg/cm2 )
All Models 35 (2.5)
MANUAL BLEEDING
NOTE: When bleeding disc brakes, air may tend to cling to caliper walls. Lightly tap
caliper, while bleeding, to aid in removal of air.
1. Fill master cylinder. Install bleeder hose to first bleeder valve to be serviced. See BLEEDING
SEQUENCE table. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
2. Open bleeder valve 3/4-1 turn. Depress brake pedal slowly through full travel. Close bleeder valve and
release pedal. Repeat procedure until flow of fluid shows no signs of air bubbles.
1984 Dodge Caravan
Fig. 1: Wheel Cylinder Bleeding Procedure

Courtesy of CHRYSLER MOTORS.
1984 Dodge Caravan
BLEEDING SEQUENCE
Before bleeding system, exhaust all vacuum from power unit by depressing brake pedal several times. Bleed
master cylinder if equipped with bleeder screws. Bleed slave cylinder on vehicles equipped with remote mount
power assist units. Bleed wheel cylinders and calipers in sequence. See BLEEDING SEQUENCE table. Use
DOT 3 for brake fluid.
BLEEDING SEQUENCE
Application Sequence
All Models RR, LR, RF, LF
ADJUSTMENTS
BRAKE BOOSTER PUSH ROD
Push rod length is preset at factory and is non-adjustable.
DISC BRAKE PADS
Pad wear is automatically compensated for by piston moving outward in cylinder bore; therefore, no disc pad
adjustment in service is required. Inspect disc pads whenever wheels are removed.
Measure shoe and lining assembly at its thinnest part. When an assembly is worn to approximately 5/16" (7.94
mm), replace both inner and outer pads on both front wheels.
DRUM BRAKE SHOES
1. Raise and support vehicle. Ensure parking brake lever is fully released and back off parking brake cable
adjustment to ensure cable has slack. Remove adjusting hole cover.
2. Using adjustment tool (C-3784), expand brake shoes until slight drag is felt when wheel assembly is
rotated. Using thin screwdriver, hold automatic adjusting lever away from adjustment star wheel.
3. Back off adjustment star wheel just until wheel assembly rotates freely and brake shoe drag is eliminated.
Repeat adjustment for remaining wheels. Adjustment must be equal at all wheels. Replace adjusting hole
covers and adjust parking brake.
1984 Dodge Caravan
Fig. 2: Exploded View of Chrysler Type Brake Assembly

Courtesy of CHRYSLER MOTORS
PARKING BRAKE
Truck and FWD Van
1. With service brakes fully adjusted and parking brake fully released, loosen cable adjusting nut to allow
slack in cable. Tighten cable adjusting nut until a slight drag is felt while rotating rear wheels.
2. Loosen cable adjusting nut until both rear wheels can be rotated freely. Back off adjusting nut an
additional 2 turns. Apply and release parking brake several times, checking for free rotation at rear
wheels.
All Others
1. Raise vehicle high enough to gain access to equalizer and cable adjuster. Make sure parking brake cable
adjuster is fully released. Loosen adjuster so there is slack in both cables.
2. Make sure rear brakes are correctly adjusted. Tighten cable adjusting nut at the adjuster until a slight drag
is felt while rotating the wheel.
3. Loosen adjusting nut until both wheels can be rotated freely. Apply and release parking brake. Ensure
wheels rotate freely without any brake drag. Lower vehicle.
1984 Dodge Caravan
ROTOR SERVICING
NOTE: Minimum rotor thickness is cast into outer surface of all rotors.
RWD MODELS
1. With vehicle supported on safety stands and wheel assemblies removed, mount dial indicator on steering
arm with indicator plunger against braking surface (about 1" from edge of disc).
2. Temporarily adjust wheel bearings to zero end play. Measure runout on both sides of disc. If runout on
either side exceeds .004" (.10 mm), resurface or replace disc assembly.
3. Using micrometer, measure thickness of disc at 12 equally spaced locations around disc about 1" from
edge. If measurements vary more than .0005" (.013 mm), resurface or replace disc assembly.
4. Replace disc if it is badly scored or warped and machining does not correct defects. When refinishing,
always remove equal amounts of material, to a maximum of .030" (.76 mm) total from both sides,
.015" (.38 mm) from each face.
NOTE: Minimum rotor thickness after machining should not be less than .030"
above minimum thickness specification cast on hub.
5. All disc assemblies have minimum thickness markings on unmachined surface between wheel studs.
Markings include .030" (.76 mm) allowable wear, beyond recommended resurfacing limits of .030" (.76
mm) total, .015" (.38 mm) each side.
FWD MODELS
1. On FWD models, total runout is the sum of the rotor and hub runout. Remove wheel assemblies and
reinstall lug nuts.
2. Mount dial indicator on steering arm with plunger contacting rotor approximately 1" (25.4 mm) from
edge of disc. Runout on either side of disc should not exceed .005" (.127 mm).
3. If runout exceeds specification, check runout of hub face. Before removing rotor, make a chalk mark
across both the disc and 1 wheel stud. Make the mark on the high side of runout. Remove disc from hub.
4. Install dial indicator on steering arm with stem contacting hub face near outer diameter. Place dial
indicator stem outside the stud circle but inside the chamfer on the hub rim.
5. If runout exceeds .002" (.051 mm), hub must be replaced. If hub runout is within specification, install
rotor on hub with chalk marks 180° apart. Install wheel lug nuts and recheck rotor runout.
6. Replace or reface rotor if runout is still excessive. Remove as little as possible from each side of rotor.
7. Measure thickness at 12 equal points with a micrometer at a radius approximately 1" (25.4 mm) from
edge of rotor. If thickness varies by more than .0005" (13 mm), rotor should be resurfaced or replaced.
Replace if cracks or burns are evident on the rotor.
REMOVAL & INSTALLATION

AXLE BEARING & SEAL - W/8 3/8" OR 9 1/4" RING GEAR
1984 Dodge Caravan
Removal & Installation
1. Raise and support vehicle. Remove rear wheel assembly and brake drum. Loosen differential housing
cover bolts, drain lubricant and remove cover. Turn differential case to gain access of pinion shaft lock
screw.
2. Remove differential pinion shaft lock bolt and pinion shaft. Push flange end of axle shafts toward center
of vehicle and remove "C" lock clips from recessed groove on axle shaft.
3. Remove axle shaft from housing. Inspect axle shaft bearing surface for wear and damage. Remove oil
seal from housing bore. Using attachment (C-637) on end of slide hammer, remove bearing.
4. If bearing or shaft is worn or damaged, both should be replaced. If bearing shows no signs of distress,
reinstall bearing with new seal. Install axle shaft and complete installation by reversing removal
procedure.
AXLE BEARING & SEAL - ALL OTHERS
Removal and Installation
1. Raise and support vehicle. Remove wheel assembly and brake drum. Remove axle shaft flange nuts and
lock washers. Using hammer, sharply strike center of axle flange to free dowels.
2. Remove dowels and axle shafts. To install, clean gasket surface and install new flange gasket. Install axle
shaft, dowels, lock washers and nuts. Tighten nuts. Install wheel assembly, brake drum and lower vehicle.
BRAKE BOOSTER
NOTE: Power brake unit can be removed without removing master cylinder or
disconnecting brake lines.
Removal
1. Disconnect vacuum line from check valve or power unit. Remove nuts securing master cylinder to power
unit.
2. Pull master cylinder forward away from unit. Disconnect brake pedal from push rod. Remove power unit-
to-firewall nuts and remove unit.
Installation
To install, reverse removal procedures. Tighten master cylinder and booster mounting nuts to 13-25 ft. lbs. (18-
33 N.m).
DISC BRAKE CALIPER
Brake caliper removal and installation procedures are same as for disc brake pads, except it will be necessary to
disconnect and plug hydraulic brake hose at caliper.
DISC BRAKE PADS - BENDIX CALIPER
1984 Dodge Caravan
Removal
1. Siphon fluid from master cylinder until cylinder is 1/3 full. Raise and support vehicle with safety stand.
Remove wheel. Using a "C" clamp, bottom caliper piston in cylinder bore.
2. Remove clamp. Remove support key retaining screw. Using brass punch, drive out caliper support key
and spring. Remove caliper from adapter and pry outer shoe from caliper.
3. Using wire, hang caliper to avoid straining brake hose. Remove inner disc pad and anti-rattle spring from
adapter. If pads are being reused, mark them to ensure installation in same position.
Installation
1. Install anti-rattle spring in adapter, ensuring loop portion of spring is away from disc. Install inner disc
pad in adapter, making sure clips remain in position.
2. Place outer disc pad in position on caliper. If disc pad cannot be installed by hand, press into place using a
block of wood and a "C" clamp.
3. Place caliper into position over disc. Position brake caliper on adapter, making sure hose is not twisted.
Place spring over caliper key. Install assembly between adapter and lower caliper machined surface and
tap into place using brass punch and hammer.
4. Install support key retaining screw, making sure boss on screw fits fully into cut-out on key. Install wheel
and tire. Refill reservoir to within 1/4" of top. Pump brake pedal several times and recheck fluid level.
DISC BRAKE PADS - CHRYSLER CALIPER
Removal
1. Raise and support vehicle with safety stands. Remove wheel assembly. Remove caliper retainer and anti-
rattle spring assemblies. Carefully lift caliper assembly out and away from disc.
2. Pry between outer disc pad and fingers of housing to remove outer pad. Support caliper to prevent
damage to brake line and remove inner disc pad.
Installation
1. Slowly push piston back into caliper. Care must be taken to ensure reservoir does not overflow while
pushing in on piston. Slide outer disc pad into caliper.
2. There should be no free play between disc pad flange and caliper flange. If free play exists, bend disc pad
flange until interference fit with caliper is obtained.
3. If necessary, install disc pad using a "C" clamp and wood block placed across disc pad. Place inner lining
on adapter with disc pad flanges aligned with flange ways in adapter.
4. Slide caliper into position in adapter and over disc. Align caliper on adapter, taking care not to pull dust
boot away from groove in piston.
5. Install anti-rattle springs and retaining clips, ensuring anti-rattle spring is installed on top of retainer
spring plate. Tighten retaining screws to 200 INCH lbs. (23 N.m).
6. Pump brake pedal several times to obtain firm pedal. If firm pedal cannot be obtained, bleed brake
system. Recheck fluid level in master cylinder reservoir.
1984 Dodge Caravan
DISC BRAKE PADS - KELSEY-HAYES CALIPER
Removal
1. Raise and support vehicle. Remove front wheels. Remove caliper guide pin. See Fig. 9 . Pry the caliper
away from the adapter and pads to break the gasket adhesive seals.
2. Lift caliper assembly off adapter. DO NOT allow to hang by brake hose. Remove outer pad. Remove disc
rotor from hub and lift off inner pad.
Installation
1. Clean all caliper and adapter mating surfaces with a wire brush. Lubricate mating surfaces with multi-
purpose grease.
2. Install anti-rattle clips on top of inner pad, on bottom of outer pad, and on top finger of caliper. Remove
protective paper from noise suppression gasket on inner and outer pads. Install inner pad, rotor, and outer
pad.
3. Install caliper assembly and guide pin. Tighten pin to specification.
4. Install wheel assemblies. Tighten stud nuts in proper sequence until all 4 are tightened to half
specification. Then repeat to full specification. Pump brake pedal to obtain firm pedal. Check master
cylinder fluid level.
DISC BRAKE ROTOR - FWD MODELS
Removal & Installation
Raise and support front of vehicle. Remove wheel and tire assembly. Remove caliper. Remove rotor from drive
hub. Clean both sides of rotor with alcohol or suitable solvent. Reverse removal procedure to complete
installation.
DISC BRAKE ROTOR - W150, W250, AW150
Removal
1. Remove locking hub assembly. Raise vehicle and support with safety stands. Remove brake caliper
without disconnecting brake line. Support or suspend caliper and remove inner disc pad.
2. Using removal/installation tool (C-4170), remove wheel bearing adjusting lock nut. Remove locking ring
and wheel bearing adjusting nut. Remove rotor assembly. Outer wheel bearing and retainer spring plate
will slide out as rotor assembly is removed.
Installation
1. Mount rotor on spindle and install outer wheel bearing. Install inner lock nut using installation tool,
tighten to 50 ft. lbs. (68 N.m) to seat bearings.
2. Loosen inner lock nut and while rotating hub, retighten to 30-40 ft. lbs. (41-54 N.m). Back off inner lock
nut 135 to 150°. Install locking washer making certain pin on lock nut enters hole in locking washer.
3. Install outer lock nut and tighten to 50 ft. lbs. (68 N.m). Disc hub end play should between .001-
1984 Dodge Caravan
.010" (.03-.26 mm). Install caliper assembly. Reverse removal procedure to complete installation.
DISC BRAKE ROTOR - W250 AND W350
Removal
1. Prop brake pedal in up position. Raise vehicle and support with safety stands. With wheel assembly
removed, remove key retaining Allen screw holding caliper to adapter.
2. Tap adapter lock and spring from between caliper and adapter. Remove brake caliper without
disconnecting brake line and suspend with wire or support. Remove grease cover from end of hub and
snap ring from drive axle.
3. Remove flange nuts and lock washers. Remove flange and discard gasket. Straighten lock tabs on outer
wheel bearing lock ring. Using socket (DD-1241-JD), remove outer lock nut, lock ring, inner nut and
outer wheel bearing. Remove rotor assembly.
Installation
1. Install rotor assembly on spindle. Install outer bearing and inner lock nut. Using socket and rotating disc,
tighten lock nut to 50 ft. lbs. (68 N.m) to seat bearing.
2. Loosen inner lock nut and while rotating disc, retighten lock nut to 30-40 ft. lbs. (41-54 N.m). Back off
inner lock nut 135° to 150°. Install lock ring and outer lock nut. Tighten lock nut to 65 ft. lbs. (88 N.m).
3. Secure nut with tab on lock ring. Install drive flange with gasket and tighten bolts to 30-40 ft. lbs. (41-54
N.m). Reverse removal procedure to complete installation.
DISC BRAKE ROTOR - ALL OTHERS EXCEPT FWD MODELS
Removal
1. Raise vehicle and support with safety stands. Remove brake caliper without disconnecting brake line.
Suspend caliper with wire to avoid straining hose.
2. Remove grease cover from end of hub. Remove cotter pin, nut lock, nut, thrust washer, and outer wheel
bearing. Pull rotor assembly off wheel spindle.
Installation
1. Slide rotor assembly into position on spindle. Install outer wheel bearing, thrust washer and nut. While
rotating rotor assembly, tighten wheel bearing adjusting nut to 240-300 INCH lbs (27-33 N.m) on 4WD,
90 INCH lbs. (10 N.m) on 2WD.
2. Back off adjusting nut to release preload and retighten nut finger tight. Install cotter pin. Coat inside of
grease cover with grease and install. Reverse removal procedure to complete installation.
DRUM BRAKE SHOES - CHRYSLER TYPE
Removal
1. With drum removed, note that secondary spring overlaps primary spring and remove brake shoe return
springs using tool (C-3785). Slide automatic adjuster cable off anchor. Disconnect cable from adjusting
1984 Dodge Caravan
lever.
2. Remove cable, cable guide, and anchor plate. Disengage adjusting lever from spring and remove spring
and lever from pivot. Remove shoe-to-shoe spring, spread shoes and remove adjustment star wheel.
3. Remove shoe retainers, springs and nails. Remove parking brake lever from secondary shoe. Remove
both shoes and strut with anti-rattle springs. Detach parking brake lever from cable.
Installation
1. Apply thin coat of multi-purpose grease to 6 shoe contact pads on support plate. Attach parking brake
lever to cable and install lever in rectangular hole in secondary shoe.
2. Place secondary shoe against support plate ensuring push rod and anchor are properly positioned. Insert
strut into slot in parking brake lever. Slide anti-rattle spring over free end of strut.
3. Ensure tab on anti-rattle spring is located behind web of shoe and pointed forward and down. Install
primary shoe, ensuring push rod and strut are properly positioned.
4. Install anchor plate and eye of adjusting cable over anchor. Install primary return spring. Position cable
guide over hole in secondary shoe and install secondary return spring.
NOTE: Left adjustment star wheel is stamped "L" and cadmium plated, right is
stamped "R" and black.
5. Install adjustment star wheel with wheel next to secondary shoe. Install shoe-to-shoe spring, engaging in
primary shoe first with coil on opposite side of adjusting lever. Install adjusting lever spring over pivot
pin.
6. Install adjusting lever under spring and over pivot. Slide lever rearward to lock in position. Install shoe
nails, springs and retainers. Thread adjuster cable over guide and hook end of overload spring in lever.
DRUM BRAKE SHOES - BENDIX TYPE
Removal
1. With drum removed, disconnect adjusting lever return spring from lever. Remove lever and return spring
from pivot pin. Disconnect adjusting lever from cable. Remove upper shoe-to-shoe spring.
2. Disconnect and remove shoe retainers, springs and nails. Disconnect parking brake cable from lever.
Remove lower shoe-to-shoe spring. Remove shoes and adjustment star wheel as an assembly.
Installation
NOTE: Adjustment star wheel on left brake assembly has left-hand threads, right side
assembly has right-hand threads.
1. Lubricate and assemble adjustment star wheel. Apply thin film of multi-purpose grease to shoe contact
pads on support plate. Assemble lower shoe-to-shoe spring, adjustment star wheel and both shoes.
2. Position shoe assembly on support plate. Attach parking brake cable to lever. Install shoe nails, springs
and retainers. Install upper shoe-to-shoe spring.
3. Position adjusting lever return spring on pivot, ensuring yellow spring is on left brakes and black spring is
1984 Dodge Caravan
on right. Install adjusting lever. Route cable and connect to adjuster.
Fig. 3: Exploded View of Bendix Type Brake Assembly

Removal
1. Disconnect front and rear hydraulic brake lines at master cylinder, and cover ends to prevent entry of
foreign matter.
2. On vehicles without power assist units, disconnect brake pedal push rod at brake pedal. Remove master
cylinder retaining bolts, and remove cylinder assembly from vehicle.
Installation
1. Position master cylinder on vehicle and install cylinder retaining bolts. Connect front and rear hydraulic
brake lines to cylinder.
2. Connect brake pedal push rod, if removed. Fill reservoir with clean brake fluid, and bleed hydraulic
system. See BRAKE SYSTEM BLEEDING in this article.
MASTER CYLINDER - CHRYSLER ALUMINUM W/POWER BRAKES
Removal
1984 Dodge Caravan
Disconnect primary and secondary brake lines from master cylinder and plug outlets. Remove nuts that retain
cylinder to power brake unit. Slide master cylinder straight out and away from brake unit.
Installation
Position master cylinder over studs of power brake unit, aligning power cylinder brake push rod with cylinder
piston. Install and tighten nuts. Connect both brake lines and bleed system. Refer to BRAKE SYSTEM
BLEEDING in this article.
MASTER CYLINDER - CHRYSLER ALUMINUM W/MANUAL BRAKES
Removal
1. Disconnect primary and secondary brake lines from master cylinder and plug outlets. Disconnect stop
light switch mounting bracket under instrument panel.
2. Grasp brake pedal and pull back to disengage push rod from master cylinder. This will destroy push rod
retention grommet. Remove nuts retaining master cylinder to cowl panel. Slide master cylinder straight
out and away from cowl.
Installation
1. Install new push rod retention grommet. Position master cylinder to cowl panel. Install and tighten nuts.
Connect and tighten brake lines.
2. From under instrument panel, moisten push rod grommet with water and align push rod with master
cylinder piston. Using brake pedal, apply pressure to fully seat push rod into piston.
3. Install master cylinder boot and connect stop light switch mounting bracket. Bleed system. See BRAKE
SYSTEM BLEEDING in this article.
1984 Dodge Caravan
1984 Dodge Caravan
Fig. 4: Exploded View of Aluminum Master Cylinder

Removal
Disconnect front and rear hydraulic brake lines at master cylinder. Remove nuts retaining nuts to power brake
unit. Lift master cylinder from vehicle.
Installation
Position master cylinder on vehicle and install retaining nuts. Tighten to 200 INCH lbs. (22.7 N.m). Connect
front and rear hydraulic brake lines. Fill reservoir with clean brake fluid and bleed entire brake system. See
BRAKE SYSTEM BLEEDING in this article.
WHEEL CYLINDERS
Removal
Remove wheel, drum, and brake shoes. Inspect boots for damage and signs of leakage. Disconnect hydraulic
brake line from cylinder, remove attaching bolts and remove cylinder.
Installation
Apply RTV to cylinder mounting surface and position cylinder on support plate. Install mounting screws and
tighten. Reverse removal procedure to complete installation. Replenish fluid and bleed hydraulic system.
OVERHAUL
BRAKE BOOSTER
NOTE: Manufacturer does not recommend overhaul of power brake unit. Replace unit if
defective.
Fig. 5: Exploded View of Bendix Single Diaphragm Assembly
1984 Dodge Caravan
Fig. 6: Exploded View of Bendix Tandem Diaphragm Unit

DISC BRAKE CALIPER
Disassembly (All Models)
1. Raise vehicle and support with safety stands. Remove wheel assembly. Remove retainer and anti-rattle
spring assemblies. Carefully slide caliper out and away from disc and support assembly on axle and
steering linkage.
2. Carefully depress brake pedal to hydraulically push piston out of bore in caliper. Pedal will fall away
when piston has passed bore opening. Prop pedal in any position below first inch of travel to prevent fluid
loss.
CAUTION: Under no conditions should air pressure be used to remove piston

from bore.
3. Disconnect brake hose and remove caliper from vehicle. Remove dust boot. Work seal out of groove in
piston bore with a wooden or plastic rod to prevent damage to cylinder. Remove bushings from Kelsey-
1984 Dodge Caravan
Hayes calipers.
Inspection
1. Clean all parts with alcohol and blow dry with compressed air. Inspect piston bore for scoring or pitting.
2. Light scratches or corrosion can be removed by honing, providing bore diameter is not increased more
than .002" (.05 mm) on all calipers except Kelsey-Hayes models. Kelsey-Hayes caliper must not be
increased by more than .001" (.025 mm). Discard used piston seal and boot.
Reassembly (Bendix)
1. Lubricate new piston seal with clean brake fluid and install into groove in cylinder bore, working around
circumference with fingers until fully seated. Ensure seal is not twisted.
2. Lubricate new piston boot with brake fluid, and install into caliper by working into outer groove. Plug
inlet and bleeder screw hole.
3. Lubricate piston and, with fingers spreading boot, press piston into boot until boot is forced into groove
around piston. Remove plug. Carefully push piston down until bottomed in cylinder.
Reassembly (Chrysler)
1. Lubricate new piston seal with brake fluid and install to groove in bore, working around circumference
with fingers until fully seated. Ensure seal is not twisted.
2. Coat new piston boot with brake fluid, leaving generous amount inside boot. Place dust boot over piston.
Install piston into bore, pushing past piston seal until bottomed in bore.
3. Position dust boot in counterbore. Using boot installer tools (C-4890 and C-4171), drive boot into
counterbore. Be careful to avoid cocking seal. Install disc pads and caliper.
Reassembly (Kelsey-Hayes)
1. Coat new piston seal with clean brake fluid and install in caliper groove bore. Seal must be fully seated.
2. Lubricate dust boot and piston with clean brake fluid. Position dust boot over piston. Install piston into
bore. Push it past the seal until it bottoms in the bore.
3. Position dust boot in counterbore. Using a hammer and installer tool (C-4842) drive boot into
counterbore.
4. Compress flanges of guide pin bushings in with fingers and work into position by pressing in on
bushings. Ensure flanges extend over caliper casting evenly on both sides.
1984 Dodge Caravan
Fig. 7: Exploded View of Chrysler Single Piston Sliding Caliper

1984 Dodge Caravan
Fig. 8: Exploded View of Bendix Single Piston Sliding Caliper

1984 Dodge Caravan
Fig. 9: Exploded View of Kelsey-Hayes Caliper (FWD Models)

Disassembly
1. Clean outside of cylinder thoroughly and remove cover. Drain fluid, and turn cylinder over, pump piston
to remove any remaining fluid.
2. On manual brake models, remove boot from cylinder to uncover push rod retainer. Pry up retainer tab to
release retainer.
3. On all models, push piston down into cylinder bore. Remove secondary piston stop bolt from front fluid
reservoir (if equipped). Remove snap ring from groove in cylinder bore.
4. Remove both piston assemblies. Remove any internal parts remaining in bore. Remove and discard all
rubber parts from piston assemblies.
5. Enlarge holes in tube seats using a 13/64" drill. Place a large flat washer over outlets and thread a 1/4" x
20 x 3/4" screw into seat. Remove seat, screw and washer. Push upward with 2 screwdrivers to remove
seat.
1984 Dodge Caravan
Fig. 10: Removing Tube Seat from Master Cylinder

Inspection
Inspect cylinder bore for scoring or corrosion. Staining which has not pitted or roughened surface of cylinder
can be removed with crocus cloth. If cylinder bore is scored, pitted or corroded, it should be replaced.
Reassembly
1. Install replacement tube seats by threading a spare brake line tube nut into hole. Turn nut in until tube seat
bottoms. DO NOT cock tube seat in hole.
2. Remove nut and check for burrs which may have been loosened by nut. Install piston cups on secondary
piston, with cup lips facing away from each other.
3. Install seal protector, piston seal, spring retainer and return spring on secondary piston. Install seal so lip
1984 Dodge Caravan
faces interior of master cylinder when installed.

4. Lubricate cylinder bore with clean brake fluid and install secondary piston assembly. Lubricate primary
piston seals and install primary piston assembly in bore.
5. Hold primary piston down in bore and install snap ring in groove in bore. Install secondary piston stop
bolt (if equipped). Install master cylinder reservoir, grommets and quick take-up valve (if removed).
6. Install master cylinder cover and new diaphragm. On vehicles with manual brakes, assemble brake pedal
push rod through retainer (if used), and push retainer over end of master cylinder. Install rubber boot over
push rod.
Fig. 11: Exploded View of Typical Master Cylinder

MASTER CYLINDER - CHRYSLER ALUMINUM DUAL PISTON
Disassembly
1. Clean outside of reservoir and cylinder body. Remove reservoir caps and empty brake fluid. Position
cylinder body in vise and rock reservoir from side to side, to remove from cylinder. Remove grommets.
1984 Dodge Caravan
2. Remove secondary piston retainer pin. Remove snap ring from inside master cylinder body. Slide primary
piston out of bore.
3. Tap open end of cylinder on bench to remove secondary piston. If piston sticks, use air pressure to force
piston from cylinder. If brass tube seats are damaged or worn, use screw extractor to remove seats.
Inspection
Wash master cylinder bore with brake fluid. Inspect bore for pitting, scratches or scoring. Inspect piston for
corrosion and scoring, replace as necessary. During overhaul, all rubber parts must be replaced.
NOTE: DO NOT hone aluminum master cylinder. If bore is unserviceable, replace

cylinder.
Reassembly
1. Dip master cylinder and all components in clean brake fluid. Assembling seals dry could ruin seals.
2. Install check flow washer on secondary piston and carefully work primary cup on end with lip facing
away from piston. Slide cup retainer over front end of piston followed by spring.
3. Carefully work piston secondary cup into cylinder bore, with lip away from piston. Install secondary
piston into bore. Be careful that lip of cups enters bore evenly in order not to damage sealing of cups.
4. Carefully work secondary cup over rear end of primary piston with larger lip of cup toward piston. Center
spring retainer of primary piston on secondary piston. Push piston assemblies into bore up to primary
piston cup.
5. Carefully work cup into bore and push piston into secondary seal. Work lip of primary cup into bore and
push in on piston until seated. Depress piston with brass or wood rod and install snap ring.
6. Position secondary piston retainer pin in cylinder housing and tap or press in until firmly seated. Install
tube seats. Install housing-to-reservoir grommets and, using rocking motion, install reservoir on master
cylinder body.
NOTE: Reservoir is keyed to prevent installation in wrong direction.
Disassembly
1. Clean outside of cylinder and remove cover to drain brake fluid. Use screw extractor to remove tube
seats. Remove snap ring from open end of cylinder and slide washer out.
2. Carefully remove primary piston assembly and slide secondary piston from cylinder. Clean all parts in
alcohol and blow dry with compressed air.
Inspection
1. Inspect cylinder bore for scoring or pitting. Light scratches or minor corrosion can usually be removed by
using crocus cloth.
2. Deep scratches or scoring may be honed, provided bore diameter is not increase more that .002" (.05
1984 Dodge Caravan
mm). If this limit is exceeded, master cylinder must be replaced.

3. Check pistons for scoring, scratches and corrosion. Pistons must be replaced if any of these conditions
exist. Replace all rubber parts when overhauling master cylinder.
Reassembly
1. Dip all components in brake fluid before reassembly. Carefully slide secondary piston assembly into
cylinder bore. Slide primary piston into bore, hold washer in position and install snap ring. Install tube
seats.
2. Clamp master cylinder in a vise, being careful not to damage housing. Attach bleed tubes (C-4029) to
outlet ports of cylinder, with ends of tubes placed in master cylinder reservoirs.
3. Fill reservoirs with clean brake fluid and depress push rod slowly. Allow pistons to return to normal
position under spring pressure.
4. Repeat procedure until all air bubbles are expelled. Remove bleeding tubes, and install cylinder cover and
diaphragm. Remove cylinder from vise.
Fig. 12: Exploded View of Chrysler Cast Iron Master Cylinder

WHEEL CYLINDERS
Disassembly
1984 Dodge Caravan
Remove rubber boots from ends of cylinders. Remove cylinder push rods. Press in on one piston to force
pistons, cups, spring and cups expanders from bore. Remove bleeder screw and inspect cylinder bore for
damage.
Cleaning and Inspection
1. Clean cylinder and parts thoroughly in brake fluid or alcohol and dry with compressed air. Inspect
cylinder for pits and scratches. Replace cylinder if badly pitted or scratched.
2. Correct light scratches or pits using crocus cloth with circular motion or cylinder hone. Black stains on
walls are caused by piston cups and are normal conditions.
Reassembly
1. Coat new cups and pistons and cylinder bore with clean brake fluid. Install expansion spring with cup
expanders in cylinder. Install cup in each end of cylinder, with open ends facing each other.
2. Install piston in each end of cylinder with flat side of piston toward cup. Install boot over each end of
cylinder ensuring boot seats properly against cylinder shoulder. Lubricate end of push rods and insert into
each boot.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Axle Shaft Flange
3/8" 35-55 (47-75)
7/16" 40-70 (54-95)
1/2" 65-105 (88-142)
Durlock 60 (81)
Brake Line-to-Master Cylinder 12 (17)
Caliper
Guide Pin (Kelsey-Hayes) 25-35 (34-47)
Retaining Bolt (Chrysler) 14-22 (19-30)
Support Key Screw (Bendix) 15 (20)
Caliper Adapter Bolts
All with 1/2" Bolts 95-125 (129-170)
All with 5/8" Bolts 140-180 (190-245)
Differential Cover Bolts 21 (28)
Master Cylinder Retaining Nuts 17 (23)
Pedal Link Bolt 30 (41)
Support Plate Mounting Nuts
3/8" 35-55 (47-75)
7/16" 40-70 (54-95)
1/2" 65-105 (88-142)
1984 Dodge Caravan
Durlock 60 (81)
Wheel Cylinder Mounting Bolts 11-19 (15-26)
BRAKE SYSTEM SPECIFICATIONS

DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS

Application In. (mm)
AD150, AW150, D150, B150/250 & W150
Disc Diameter 11.75 (298.5)
Lateral Runout .004 (.10)
Parallelism .0005 (.013)
Original Thickness 1.25 (31.8)
Minimum Refinish Thickness 1.21 (30.7)
Discard Thickness 1.18 (29.97)
B350 & D250 (1)
Laterial Runout .004 (.10)
B350 & D250 (2)
W250/350
Laterial Runout .005 (.13)
FWD Models (3)
Disc Diameter 10.6 (270)
1984 Dodge Caravan
Original Thickness .870 (22.09)

Minimum Refinish Thickness N/A
Discard Thickness .803 (20.39)
(1) For vehicles with 4000 lbs. front axle.
(2) For vehicles with 3600 lbs. front axle.
(3) FWD vans with extended wheelbase or 15" wheels may have different disc specifications not
available at time of publication. Specifications may be stamped or cast into disc hub.
DRUM BRAKE SYSTEM SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS

Application In. (mm)
Chrysler Type (FWD Models)
Disc Diameter 9 (231)
Drum Width N/A
Maximum Drum Refinish Diam. 9.06 (230.1) (1)
Wheel Cylinder Diameter 0.75 (19.0)
Master Cylinder Diameter 0.95 (24.1)
Chrysler Type (RWD Models)
Drum Width 2.50 (63.5)
Maximum Drum Refinish Diameter 11.06 (280.9) (1)
Wheel Cylinder Diameter 0.94 (23.8)
Bendix Type
Drum Width 3.00 (76.2) (2)
Maximum Drum Refinish Diameter 12.06 (306.3) (1)
Wheel Cylinder Diameter 1.00 (25.4) (3)
(1) Maximum diameter stamping on drum exceeds recommended maximum drum refinishing
specification. Stamping includes .030" (.76 mm) allowable drum wear beyond recommended
maximum specification.
(2) All models except: D250 and D350 with Spicer 44 front axle; B-350 w/3600 front axle and B-350
with 8510 GVWR and 4000 front axle. These have 2.50" (63.5 mm) width.
(3) All models with 2.50" (63.5 mm) drum width only. Bore diameter on models with 3.00" drum width
are: 1.125" (28.58 mm) on trucks, 1.06" (26.9 mm) on vans and wagons.

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1984 Dodge Caravan

BRAKE SYSTEM 1984 BRAKES Chrysler Motors - Brake System

1984 BRAKES Chrysler Motors - Brake System

BRAKE BOOSTER - BENDIX TANDEM DIAPHRAGM

MASTER CYLINDER - BENDIX/DELCO-MORAINE DUAL PISTON

NOTE: Optional on Dodge W250/350 & D350 only.

viernes, 29 de mayo de 2020 07:58:46

MASTER CYLINDER - CHRYSLER ALUMINUM DUAL PISTON

MASTER CYLINDER - CHRYSLER CAST IRON DUAL PISTON

BRAKE SYSTEM BLEEDING

NOTE: Hydro-Boost bleeding is a different procedure than hydraulic brake bleeding.

HYDRAULIC CONTROL VALVES

PRESSURE TANK BLEEDING

instructions unless noted below.

PRESSURE BLEEDER SETTINGS

Fig. 1: Wheel Cylinder Bleeding Procedure

Push rod length is preset at factory and is non-adjustable.

DISC BRAKE PADS

DRUM BRAKE SHOES

Fig. 2: Exploded View of Chrysler Type Brake Assembly

Truck and FWD Van

REMOVAL & INSTALLATION

Removal & Installation

AXLE BEARING & SEAL - ALL OTHERS

Removal and Installation

DISC BRAKE CALIPER

DISC BRAKE PADS - BENDIX CALIPER

DISC BRAKE PADS - CHRYSLER CALIPER

DISC BRAKE PADS - KELSEY-HAYES CALIPER

DISC BRAKE ROTOR - FWD MODELS

Removal & Installation

DISC BRAKE ROTOR - W150, W250, AW150

DISC BRAKE ROTOR - W250 AND W350

DISC BRAKE ROTOR - ALL OTHERS EXCEPT FWD MODELS

DRUM BRAKE SHOES - CHRYSLER TYPE

DRUM BRAKE SHOES - BENDIX TYPE

on right. Install adjusting lever. Route cable and connect to adjuster.

Fig. 3: Exploded View of Bendix Type Brake Assembly

MASTER CYLINDER - BENDIX/DELCO-MORAINE DUAL PISTON

MASTER CYLINDER - CHRYSLER ALUMINUM W/POWER BRAKES

MASTER CYLINDER - CHRYSLER ALUMINUM W/MANUAL BRAKES

Fig. 4: Exploded View of Aluminum Master Cylinder

MASTER CYLINDER - CHRYSLER CAST IRON DUAL PISTON

Fig. 5: Exploded View of Bendix Single Diaphragm Assembly

Courtesy of CHRYSLER MOTORS

Fig. 6: Exploded View of Bendix Tandem Diaphragm Unit

DISC BRAKE CALIPER

Disassembly (All Models)

CAUTION: Under no conditions should air pressure be used to remove piston

Fig. 7: Exploded View of Chrysler Single Piston Sliding Caliper

Fig. 8: Exploded View of Bendix Single Piston Sliding Caliper

Fig. 9: Exploded View of Kelsey-Hayes Caliper (FWD Models)

MASTER CYLINDER - BENDIX/DELCO-MORAINE DUAL PISTON

Fig. 10: Removing Tube Seat from Master Cylinder

faces interior of master cylinder when installed.

Fig. 11: Exploded View of Typical Master Cylinder

MASTER CYLINDER - CHRYSLER ALUMINUM DUAL PISTON