lock CHRYSLER CARAVAN 2005 Owner's Guide

REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 3).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch.
(3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.
(2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 3).
ADJUSTABLE PEDALS
SWITCH
REMOVAL
The adjustable pedals switch is located in the
steering column lower shroud. Remove the shroud,
then remove the switch. (Refer to 19 - STEERING/
COLUMN/LOWER SHROUD - REMOVAL)
INSTALLATION
The adjustable pedals switch is located in the steer-
ing column lower shroud. Install the switch in the
shroud, then install the shroud. (Refer to 19 - STEER-
ING/COLUMN/LOWER SHROUD - INSTALLATION)
Once installed, test for proper operation of the
adjustable pedals.
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
Each front disc brake consists of the following com-
ponents:
²Brake Rotor
²Brake Caliper
²Brake Caliper Adapter
²Shoes (Pads)
There are two non-interchangeable front disc brake
systems. One is manufactured by TRW and the other
by Continental Teves.
CAUTION: Components used on the TRW brakes
are not interchangeable with the Continental Teves
brakes. The two different systems must not be
mixed. Improper performance, noise and increased
stopping distance can occur.
The TRW front brake caliper is a one piece casting
containing a single 66 mm diameter piston bore (Fig.
4) with a phenolic piston. The caliper mounts to a
caliper adapter using two guide pin bolts that thread
into guide pins slid into the caliper adapter (Fig. 5).
The pins are lubricated and have boots that seal
them in place in the adapter.
Fig. 3 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 4 Front Disc Brake Calipers
1 - CONTINENTAL TEVES CALIPER (66 mm bore)
2 - TRW CALIPER (66 mm bore)
3 - GUIDE PIN BOLT
4 - GUIDE PIN AND BOOT
5 - CALIPER ADAPTER
6 - GUIDE PIN BOLT
7 - GUIDE PIN BUSHING
8 - CALIPER ADAPTER
RSBRAKES - BASE5-11
BRAKE FLUID LEVEL SWITCH (Continued)

As disc brake shoe linings wear, master cylinder
reservoir brake fluid level will drop. Adjust as neces-
sary. Fluid level should always be checked after
replacing shoes.
OPERATION - DISC BRAKES (REAR)
The rear disc brakes operate similarly to front disc
brakes, however, there are some features that require
different service procedures.
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER
The rear drum brakes on this vehicle automatically
adjust when required during the normal operation of
the vehicle every time the brakes are applied. Use
the following procedure to test the operation of the
automatic adjuster.
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the adjustment hole in each brake support
plate to provide visual access of the brake adjuster
star wheel.
To eliminate the condition where maximum adjust-
ment of the rear brake shoes does not allow the auto-
matic adjuster to operate when tested, back the star
wheel off approximately 30 notches. It will be neces-
sary to hold the adjuster lever away from the star
wheel to permit this adjustment.
Have the helper apply the brakes. Upon applica-
tion of the brake pedal, the adjuster lever should
move down, turning the adjuster star wheel. Thus, a
definite rotation of the adjuster star wheel can be
observed if the automatic adjuster is working prop-
erly. If one or more adjusters do not function prop-
erly, the respective drum must be removed for
adjuster servicing.
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
The brake tubes are steel with a corrosion-resis-
tant nylon coating applied to the external surfaces.
The flex hoses are made of reinforced rubber with fit-
tings at each end.
The primary and secondary brake tubes leading
from the master cylinder to the ABS ICU Hydraulic
Control Unit (HCU) or the non-ABS junction block
have a special flexible section. This flexible section is
required due to cradle movement while the vehicle is
in motion (The ICU and non-ABS junction block are
mounted to the cradle).If replacement of these
lines is necessary, only the original factory
brake line containing the flexible section must
be used.
OPERATION - BRAKE TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle's suspension.
INSPECTION - BRAKE TUBES AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference.
The brake tubing should be inspected periodically
for evidence of physical damage or contact with mov-
ing or hot components.
The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections must also be inspected. This flexible tub-
ing must be inspected for kinks, fraying and contact
with other components or with the body of the vehi-
cle.
Fig. 10 Caliper Piston Seal Function For Automatic
Adjustment
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
5 - 14 BRAKES - BASERS
HYDRAULIC/MECHANICAL (Continued)

shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were removed from.
INSTALLATION - REAR DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments where the
shoes contact with a liberal amount of MopartMul-
tipurpose Lubricant, or equivalent.
(3) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
NOTE: The outboard shoes are different left to
right. They can be identified by a L or R stamped on
the clip.
(5) Install the outboard brake shoe on the disc
brake caliper. Be sure the outboard shoe is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(6) Carefully lower caliper and brake shoes over
rotor and onto adapter, reversing the removal proce-
dure (Fig. 15).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
(8) Install the wheel and tire assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification. Then repeat
the tightening sequence to the full specified torque of
135 N´m (100 ft. lbs.).
(9) Lower vehicle.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(10) Pump brake pedal several times to set brake
shoes to rotors.
(11) Check fluid level in reservoir.(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
BRAKE PADS/SHOES - REAR
DRUM
REMOVAL - REAR DRUM BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM
- REMOVAL)
NOTE: When creating slack in the park brake cables
by locking out the automatic adjuster, (Fig. 18) be
sure that the park brake pedal is in the released
(most upward) position.
(4) Create slack in the rear park brake cables.
Slack is created by grabbing exposed section of front
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake
cable just rearward ofonly the rearbody outrigger
bracket. (Fig. 18)
Fig. 18 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RSBRAKES - BASE5-19
BRAKE PADS/SHOES - REAR DISC (Continued)

(3) Install the park brake actuator strut (Fig. 30)
on the leading brake shoe. Then install the park
brake actuator lever on the strut (Fig. 30).
(4) Install the automatic adjuster screw on the
leading brake shoe. Then install the trailing brake
shoe on the park brake actuating lever and park
brake actuating strut (Fig. 26). Position trailing
brake shoe on brake support plate.
(5) Install the brake shoe hold down pin and
spring on the trailing brake shoe (Fig. 25).
(6) Install the brake shoe to brake shoe upper
return spring (Fig. 24).
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 23). If it
is located on a non-threaded area of the adjuster, the
function of the automatic adjuster will be affected.
(7)Install the tension clip (Fig. 23) attaching the
upper return spring to the automatic adjuster assembly.
(8)Install the brake shoe to brake shoe lower return
springs on the brake shoes (Fig. 21) and (Fig. 22).
(9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 20).
(10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 19).
(11) Verify that the automatic adjuster lever has
positive contact with the star wheel on the automatic
adjuster assembly.
(12) When all components of both rear brake
assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.(13) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(14) Install the rear brake drums on the hubs.
(15) Adjust rear brake shoes.
(16) Install the wheel and tire assembly.
(17) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(18) Lower the vehicle.
(19) Push the parking brake lever (pedal) to the
floor once and release pedal. This will automatically
remove the slack from and correctly adjust the park-
ing brake cables.
(20) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE SHOES
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
NOTE: Before raising the vehicle, verify the parking
brake lever is fully released.
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove rubber plug from rear brake adjusting
hole in the rear brake support plate.
(3) Insert a thin screwdriver through the adjusting
hole in the support plate and against the star wheel
of the adjusting screw. Move handle of the tool down-
ward, rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated.
(4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel.Care should be taken so as not to bend
adjusting lever or distort lever spring.
(5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag.
(6) Repeat the above adjustment at the other rear
wheel.
(7) Install the adjusting hole rubber plugs back in
the rear brake support plates.
(8) Lower the vehicle.
Fig. 30 Park Brake Components Assembled On
Leading Brake Shoe
1 - PARK BRAKE CABLE
2 - LEADING BRAKE SHOE
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER
5 - BRAKE SUPPORT PLATE
RSBRAKES - BASE5-23
BRAKE PADS/SHOES - REAR DRUM (Continued)

INSTALLATION
INSTALLATION - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system. If
calipers are interchanged, improper performance,
noise and increased stopping distance can occur.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL -
DESCRIPTION)
(1) Completely retract the caliper piston back into
piston bore of the caliper. Use a C-clamp to retract
the piston if necessary. Place a wood block over the
piston before installing the C-clamp to avoid damag-
ing the piston.
CAUTION: Use care when installing the brake cali-
per assembly onto the steering knuckle, so that the
seals on the caliper guide pin bushings do not get
damaged by the steering knuckle bosses.
(2) Carefully position the brake caliper and shoes
over the brake rotor and adapter.
(3) Install the caliper guide pin bolts and tighten
to a torque of 35 N´m (26 ft. lbs.).Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
(4) Install the anti-rattle clip on the outboard side
of the caliper. Start the clip into the holes on the cal-
iper, then stretch the clip legs past the abutments on
the caliper adapter.
CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
copper washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special fitting washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N´m (35 ft.
lbs.).
(6) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification, then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(7) Lower the vehicle.
(8) Remove the brake pedal depressor (holding)
tool.
(9) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
INSTALLATION - FRONT DISC BRAKE CALIPER
(TRW BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system. If
calipers are interchanged, improper performance,
noise and increased stopping distance can occur.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL -
DESCRIPTION)
(1) Completely retract the caliper piston back into
the bore of the caliper. Use a C-clamp to retract the
piston if necessary. Place a wood block over the pis-
ton before installing the C-clamp to avoid damaging
the piston.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(2) Install the disc brake caliper over the brake
shoes on the brake caliper adapter.
(3) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N´m (26 ft. lbs.) (Fig.
31).
(4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 31). Install NEW copper
washers on each side of the hose fitting as the banjo
bolt is guided through the fitting. Thread the banjo
bolt into the caliper and tighten it to a torque of 47
N´m (35 ft. lbs.).
(5) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(6) Lower the vehicle.
(7) Remove the brake pedal holding tool.
(8) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - BASE - STANDARD PROCEDURE).
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
RSBRAKES - BASE5-27
DISC BRAKE CALIPER - FRONT (Continued)

FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brake hydraulic unit and all hydraulic fluid
hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Fluid reservoirs are marked with the words FULL
and ADD to indicate proper brake fluid fill level of
the master cylinder.
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.
Use only Mopartbrake fluid or equivalent from a
sealed container. Brake fluid must conform to DOT 3
specifications (DOT 4 or DOT 4+ are acceptable).
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only MopartBrake
Fluid or equivalent from a tightly sealed container.CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
located on the driver's side of the front suspension
cradle/crossmember below the master cylinder (Fig.
44).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated
control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
RSBRAKES - BASE5-33

REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block.
(2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following:
(a) Disconnect the battery positive cable.
(b) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(c) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(d) Remove the screw securing the coolant filler
neck to the battery tray.
(e) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system.
(4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 44).(5) Remove the primary and secondary brake
tubes from the top of the junction block.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.).Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
mounting nuts.
(b) Connect the wiring harness to the speed con-
trol servo.
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(d) Install the screw securing the coolant filler
neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
of the brake system.
Fig. 44 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
5 - 34 BRAKES - BASERS
JUNCTION BLOCK (Continued)

CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
50). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
46).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
PEDALS - ADJUSTABLE
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Move driver's seat to full rearward position.
(2) Disconnect negative battery cable from battery
post and isolate.
(3) Remove throttle cable from throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(4) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 53).
(5) Disconnect parking brake release link at
release handle.
(6) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.
(7) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 53).
(8) Remove hood release from lower left reinforce-
ment.
(9) Remove screws securing instrument panel
lower left reinforcement in place, then remove rein-
forcement (Fig. 54).(10) Remove brake lamp switch.Discard original
switch; it must not be reused.(Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL)
(11) Remove upper and lower steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - REMOVAL)
Fig. 53 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 54 Instrument Panel Lower Left Reinforcement
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT
5 - 40 BRAKES - BASERS
MASTER CYLINDER (Continued)

(12) Disconnect wiring harness connectors (as
equipped) from clockspring, multi-function switch,
SKIM module, ignition switch and BTSI solenoid.
(13) If equipped, disconnect PRNDL cable from
shift lever and column bracket (Fig. 55).
(14) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 55).
(15) Remove pinch side clip, then remove shift
cable from bracket on column.
(16) Place front wheels in STRAIGHT-AHEAD
position, then secure steering wheel to column in this
position using appropriate retaining method.
(17) Remove pinch bolt securing column coupling
to intermediate shaft (Fig. 56).(18)Loosen two lower steering column mounting nuts.
(19)Remove two upper steering column mounting nuts.
(20) Remove steering column assembly.
(21) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 57).
(22) Remove two nuts securing brake lamp switch
bracket to pedal assembly. Remove bracket.
(23) Disconnect wiring connector connecting vehi-
cle wiring harness connector to pedal wiring harness
(Fig. 58).
Fig. 55 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE (IF EQUIPPED)
5 - STEERING COLUMN
Fig. 56 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
Fig. 57 Intermediate Shaft Dash Seal
And Silencer Shell
1 - INTERMEDIATE SHAFT
2 - DASH SEAL
3 - SILENCER SHELL
Fig. 58 Wiring Harness Connection
1 - VEHICLE WIRING HARNESS
2 - WIRING CONNECTOR
3 - ROUTING LOOP
RSBRAKES - BASE5-41
PEDALS - ADJUSTABLE (Continued)

INSTALLATION
(1) Install adjustable pedals assembly under
instrument panel.
(2) Attach throttle cable to accelerator pedal using
cable retainer.
(3) Install two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash panel.Do not fully tighten at this time.
(4) Install four nuts attaching pedals assembly and
power brake booster to dash panel (Fig. 61).
(5) Tighten four booster mounting nuts and two
upper mounting bolts to 28 N´m (21 ft. lbs.) torque.
(6) Route pedal adjuster cable up and over right
side of pedals assembly and steering column bracket,
then down through hole in steering column bracket
as shown (Fig. 60). Attach end of cable to gear box.
(7) Place adjuster cable through loop on right side
of steering column bracket as shown (Fig. 60).
(8) Install booster input rod onto brake pedal pin
and install a NEW retaining clip.
(9) Connect wiring connector connecting vehicle
wiring harness to pedal wiring harness (Fig. 58).
(10) Connect routing clips retaining vehicle wiring
harness to pedal wiring harness (Fig. 58).
(11) Install brake lamp switch bracket on pedals
assembly. Tighten mounting nuts to 6 N´m (50 in.
lbs.) torque.
(12) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
57).
(13) Install steering column onto lower mounting
studs with nuts started, then install column onto
upper mounting studs and install two upper mount-
ing nuts. Tighten upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque.
(14) Install column shaft coupling onto intermedi-
ate shaft and install pinch bolt. Make sure rounded
side of intermediate shaft is matched to the curva-
ture of the coupling. Tighten pinch bolt to 28 N´m
(250 in. lbs.) torque.
(15) Remove retainer holding steering wheel in
place on steering column.
(16) Attach shift cable to bracket on column.
(17) Connect shift cable end to shift lever mecha-
nism pin (Fig. 55).
(18) If equipped, connect PRNDL cable to end of
shift lever mechanism pin and column bracket (Fig.
55).(19) Connect column wiring harness connectors (as
equipped) to SKIM, BTSI solenoid, ignition switch,
multi-function switch, and clockspring.
(20) Install lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - INSTALLATION)
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(21) Install and adjust NEW brake lamp switch.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION)
(22) Install instrument panel lower left reinforce-
ment (Fig. 54).
(23) Attach hood release to lower left reinforce-
ment.
(24) Install knee blocker reinforcement plate (Fig.
53).
(25) Connect parking brake release link to release
handle.
(26) Install data link diagnostic connector to
mounting hole in reinforcement plate.
(27) Install lower steering column cover/knee
blocker (Fig. 53).
(28) Install throttle cable onto throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery following special Diagnosis And Testing pro-
cedure. (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING)
(30) Test operation of adjustable pedals and all
functions that are steering column operated. If appli-
cable, reset radio and clock.
(31) Road test the vehicle to ensure proper opera-
tion of steering and brake systems.
RSBRAKES - BASE5-43
PEDALS - ADJUSTABLE (Continued)