LEMON Manuals: Even more car manuals for everyone
Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Suspension >> Wheel Alignment >> Suspension System >> Rear Suspension >> Axle-Rear >> Removal >> Rear Disc Brake Vehicles

Rear Disc Brake Vehicles

WARNING: The automatic adjusting feature of the parking brake lever contains a clockspring loaded to approximately 19 pounds. Do not release the automatic adjuster lockout device unless the rear parking brake cables and equalizer are connected to the lever output cable. Keep hands out of automatic adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury.
WARNING: When repairs to the parking brake lever or cables are required, the automatic adjuster must be loaded and locked out to avoid possible injury. The lever adjustment mechanism can be loaded and locked out as outlined in this procedure.
WARNING: The airbag system is a complex electromechanical unit. Before attempting to service any component near the Occupant Restraint Controller (ORC), first disconnect and isolate the battery negative cable. Allow the system capacitor to discharge for two (2) minutes. Failure to do this could result in accidental airbag deployment and possible personal injury.
NOTE: Before proceeding, (Refer to SUSPENSION/REAR - WARNING) .
Fig 1: Air Cleaner Cover
GC0021569Courtesy of DAIMLERCHRYSLER CORP.
  1. If applicable to access battery, unclip the air cleaner cover (two clips) and move the cover aside.
    Fig 2: BATTERY CABLES
    GC0041103Courtesy of DAIMLERCHRYSLER CORP.
  2. Disconnect and isolate the battery negative cable (1) from its post on the battery (4).
  3. Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released.
    Fig 3: CENTER CONSOLE TYPICAL
    GC0041123Courtesy of DAIMLERCHRYSLER CORP.
    1 - CENTER CONSOLE
  4. Remove the center console (1). (Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL) .
    Fig 4: Pin Punch Installed
    GC0021773Courtesy of DAIMLERCHRYSLER CORP.
    1 - PARKING BRAKE LEVER
    2 - OUTPUT CABLE
    3 - PIN PUNCH
  5. Grasp the parking brake lever (1) output cable (2) by hand and pull upward. Continue pulling on the cable until an appropriate sized pin punch (drill bit or locking pin) (3) can be inserted sufficiently through the hole in the left side of the lever mounting bracket. This will lock the parking brake automatic adjustment mechanism in place and take tension off the parking brake cables. Slowly release the output cable. There should now be slack in the cables.
    Fig 5: Parking Brake Cables At Equalizer
    GC0019738Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEVER OUTPUT CABLE
    2 - EQUALIZER
    3 - REAR PARKING BRAKE CABLES
  6. Remove the rear parking brake cables (3) from the parking brake cable equalizer (2).
  7. Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) .
    NOTE: Perform step  8. through step  23. on each side of the vehicle.
    Fig 6: Tire And Wheel Mounting Method
    GC0041085Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly.
  9. Remove the bolt securing the disc brake flex hose to the axle trailing arm.
    Fig 7: REAR DISC BRAKES, HUB AND SPINDLE
    GC0041084Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove the disc brake caliper guide pin bolts (4), then the caliper (1) from the disc brake adapter (3).
  11. Hang the caliper (1) out of the way using a wire hanger or bungee cord. Do not allow the caliper to hang by the flex hose; damage to the hose may occur. 
  12. Remove the brake rotor retaining clips (9), then the brake rotor (8).
  13. Remove the dust cap (10) from the hub and bearing (2).
  14. Remove the hub nut (11), then slide the hub and bearing (2) from the spindle (6).
    Fig 8: Parking Brake Shoes
    GC0019730Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RETURN SPRING
    2 - SHOE HOLD DOWN CLIPS
    3 - ADJUSTER
    4 - LOWER REAR SPRING
    5 - DISC BRAKE ADAPTER
  15. Remove the upper return spring (1) and both shoe hold-down clips (2), then spread the rear parking brake shoes apart at the top enough to clear the shoe anchor and remove the parking brake shoes as an assembly from the disc brake adapter (5).
    Fig 9: Parking Brake Actuator Lever
    GC0019734Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHOE ACTUATOR LEVER
    2 - SHIELD MOUNTING SCREWS
    3 - REAR PARKING BRAKE CABLE
  16. Remove the parking brake actuator lever (1) from the parking brake cable (3).
    Fig 10: Parking Brake Cable Removal
    GC0019735Courtesy of DAIMLERCHRYSLER CORP.
    1 - CABLE RETAINER
    2 - OFFSET BOX WRENCH
    3 - PARKING BRAKE CABLE
  17. Using a 1/2 inch offset box wrench (2), compress the locking fingers on the cable retainer (1), then slide the parking brake cable (3) from the rear disc brake adapter.
    Fig 11: Cable Routing Bracket Fasteners
    GC0021775Courtesy of DAIMLERCHRYSLER CORP.
    1 - CABLE
    2 - ARM
    3 - FASTENERS
  18. Remove the two bolts (3) on the axle trailing arm securing the parking brake cable (1) and routing brackets to the axle trailing arm (2).
  19. Pull the cable (1) through the hole in the trailing arm (2).
    Fig 12: REAR WHEEL SPEED SENSOR ROUTING
    GC0041243Courtesy of DAIMLERCHRYSLER CORP.
  20. On vehicles equipped with antilock brakes, remove the wheel speed sensor routing clips (2) from the axle (1) and trailing arm (3).
    Fig 13: REAR WHEEL SPEED SENSOR MOUNTING
    GC0041119Courtesy of DAIMLERCHRYSLER CORP.
  21. On vehicles equipped with antilock brakes, remove the screw (3) securing the antilock brake wheel speed sensor (2) to the disc brake adapter (1). Remove the sensor head from the adapter.
    Fig 14: REAR DISC BRAKES, HUB AND SPINDLE
    GC0041084Courtesy of DAIMLERCHRYSLER CORP.
  22. Remove the four bolts (7) securing the disc brake adapter (3) and spindle (6) to the axle.
  23. Remove the disc brake adapter (3) and spindle (6) from the axle.
    Fig 15: Watts Linkage System
    GC0043361Courtesy of DAIMLERCHRYSLER CORP.
  24. Remove the bolt (7), nut (1) and washer (2) securing the watts link bell crank (9) to the center of the axle (11). See Fig 15.
    Fig 16: STABILIZER BAR MOUNTING TO AXLE
    GC0043362Courtesy of DAIMLERCHRYSLER CORP.
  25. If equipped with a rear stabilizer bar, on each side, remove the bolt (3) securing the stabilizer bar cushion retainer (1) to the rear axle (2). Lift each retainer from the slot in the axle allowing the stabilizer bar to hang free.
  26. Position a transmission jack or equivalent under the center of the axle raising it enough to support the axle.
    Fig 17: REAR SHOCK MOUNTING
    GC0043363Courtesy of DAIMLERCHRYSLER CORP.
  27. On each side, remove the lower mounting bolt (5), nut (7) and washer (6) securing the shock absorber (2) to the axle (4).
    Fig 18: REAR COIL SPRINGS
    GC0043364Courtesy of DAIMLERCHRYSLER CORP.
  28. Lower the transmission jack until the coil springs (2) can be removed from the axle.
  29. Remove the coil springs (2) and rubber isolators (1, 3).
    Fig 19: Marking Bracket Location
    GC0021777Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCRIBED LINE
    2 - AWL
    3 - BRACKET
  30. Using an awl (2), scribe a line (1) marking the location of the axle trailing arm bracket (3), side-to-side and front-to-rear, on the body of the vehicle. Perform this for the axle trailing arm bracket on the opposite side bracket as well.
    Fig 20: TRAILING ARM MOUNTING TO BODY
    GC0043365Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove the bolts (4) securing both trailing arm forward brackets (3) to the body (2) of the vehicle.
  32. Remove the axle (1) from the vehicle.
    Fig 21: Rear Axle & Mounting Brackets
    GC0043360Courtesy of DAIMLERCHRYSLER CORP.
  33. If necessary, remove the nuts (3) and thru-bolts (1) fastening the trailing arm forward brackets (2) to the axle (4). Remove the brackets.
scientia non olet · About LEMON Manuals