booster CHRYSLER TOWN AND COUNTRY 2002 Service Manual
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Page 20 of 2399
The hoisting points are identified by S.A.E.
inverted triangle hoisting symbols (Fig. 5). The front
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250 mm
behind the front suspension crossmember. When
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate con-
tact between the hoist arm and the down standing
flange on the sill. The rear hoisting points are the
leaf spring front mounting brackets. The hoist pad
must be positioned to pick up the flanges on the
bracket, not the leaf spring.
When servicing the leaf springs or the leaf spring
mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
hoist pads under the horizontal surface on the bot-
tom of the sill, inboard adjacent to the flange and
centered fore/aft between the jacking indicator tabs
on the lower flange.DO NOT HOIST ON THE
FLANGE.Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the fin-
ish.JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS. (Refer to 8 - ELECTRICAL/BAT-
TERY SYSTEM/BATTERY - STANDARD PROCE-
DURE).
WARNING: DO NOT JUMP START A FROZEN BAT-
TERY, PERSONAL INJURY CAN RESULT.
WARNING: DO NOT JUMP START WHEN MAINTE-
NANCE FREE BATTERY INDICATOR DOT IS BRIGHT
COLOR.
WARNING: DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE.
WARNING: DO NOT USE OPEN FLAME NEAR BAT-
TERY
WARNING: REMOVE METALLIC JEWELRY WORN
ON HANDS OR WRISTS TO AVOID INJURY BY
ACCIDENTAL ARCING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT BOOST-
ING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS.
WARNING: REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: DO NOT ATTEMPT TO PUSH OR TOW
THE VEHICLE TO START IT. THE VEHICLE CANNOT
BE STARTED THIS WAY. PUSHING WITH ANOTHER
VEHICLE MAY DAMAGE THE TRANSAXLE OR THE
REAR OF THE VEHICLE.
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Clear or bright color test indicator, if equipped.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
Fig. 5 HOISTING AND JACKING POINTS
1- DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST)
2 - CHASSIS LIFT (NON-AXLE DUAL POST)
2 - OUTBOARD LIFT (DUAL POST)
2 - FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
RSLUBRICATION & MAINTENANCE0-7
HOISTING (Continued)
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Page 21 of 2399
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 6).
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - STANDARD PROCEDURE).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter may over-
heat and could fail.
(7) If engine does not start within 15 seconds, stop
cranking engine and allow starter to cool (15 min-
utes), before cranking again.DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
²AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
Fig. 6 JUMPER CABLE CLAMP CONNECTIONS
1 - BATTERY NEGATIVE TERMINAL
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR (IF EQUIPPED)
4 - BATTERY POSITIVE TERMINAL
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
0 - 8 LUBRICATION & MAINTENANCERS
JUMP STARTING (Continued)
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DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)..................26
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES).................26
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........27
DISASSEMBLY - CALIPER PISTON AND
SEAL...............................27
CLEANING - CALIPER...................28
INSPECTION - CALIPER..................28
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........28
ASSEMBLY - CALIPER PISTON AND SEAL . . 28
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DISC BRAKES)...........29
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DRUM BRAKES)..........30
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....30
DISASSEMBLY - CALIPER PISTON AND SEAL . 31
CLEANING - CALIPER...................32
INSPECTION - CALIPER..................32
ASSEMBLY - CALIPER PISTON AND SEAL . . . 32
INSTALLATION - REAR DISC BRAKE CALIPER . 33
DISC BRAKE CALIPER ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER...........................34
INSTALLATION - FRONT DISC BRAKE
CALIPER ADAPTER....................34
DISC BRAKE CALIPER GUIDE PINS
REMOVAL - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES).............34
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (DISC/DRUM BRAKES).......34
DRUM
REMOVAL.............................35
INSTALLATION.........................35
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................35
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................35
SPECIFICATIONS
BRAKE FLUID........................35
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK . 36
OPERATION - NON-ABS JUNCTION BLOCK . . 36
REMOVAL - NON-ABS JUNCTION BLOCK....36
INSTALLATION - NON-ABS JUNCTION BLOCK . 36
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................37DESCRIPTION - RHD..................38
OPERATION...........................38
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................38
REMOVAL
REMOVAL - LHD......................39
REMOVAL - RHD......................40
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................40
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................41
INSTALLATION
INSTALLATION - LHD..................41
INSTALLATION - RHD..................42
PEDAL - ADJUSTABLE
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SYSTEM......................43
REMOVAL.............................43
INSTALLATION.........................45
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................47
INSTALLATION.........................47
POWER BRAKE BOOSTER
DESCRIPTION.........................48
OPERATION...........................49
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................49
REMOVAL
REMOVAL - LHD......................50
REMOVAL - RHD......................52
INSTALLATION
INSTALLATION - LHD..................53
INSTALLATION - RHD..................55
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................56
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................57
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................57
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................58
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................59
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 59
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................61
REMOVAL - FRONT BRAKE ROTOR........62
INSTALLATION - FRONT BRAKE ROTOR.....62
SPECIFICATIONS
BRAKE ROTOR.......................63
BRAKE ROTOR - EXPORT..............63
5 - 2 BRAKES - BASERS
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SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................64
INSTALLATION.........................64
WHEEL CYLINDERS
REMOVAL.............................65
INSPECTION..........................65
INSTALLATION.........................65
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................65
DESCRIPTION - EXPORT...............66
OPERATION...........................66
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................66
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................67
CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE
(FRONT)............................67
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)......................68
REMOVAL - PARKING BRAKE CABLE
(RIGHT REAR)........................69
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)..............................70INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)............................71
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)......................71
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)........................72
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR).........................72
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 72
CABLES - PARKING BRAKE (EXPORT)
REMOVAL - FRONT CABLE...............72
INSTALLATION - FRONT CABLE............72
LEVER - PARKING BRAKE
REMOVAL.............................72
INSTALLATION.........................73
LEVER - PARKING BRAKE (EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE.......................74
INSTALLATION - PARKING BRAKE LEVER
AND FRONT CABLE...................75
SHOES - PARKING BRAKE
REMOVAL.............................75
INSTALLATION.........................81
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 83
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components:
²Brake pedal
²Power brake booster
²Master cylinder
²Brake tubes and hoses
²Proportioning valve (non-ABS vehicles only)
²Disc brakes
²Drum brakes
²Brake lamp switch
²Brake fluid level switch
²Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options.
The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other.For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)
Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.
DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly.
The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
RSBRAKES - BASE5-3
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CONDITION POSSIBLE CAUSES CORRECTION
SCRAPING (METAL-TO-
METAL).1. Foreign object interference with
brakes.1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL)1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent.5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY)1. Parking brake cables binding or
froze up.1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes.2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only).3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted.Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.2. Refer to power brake booster
diagnosis and testing.
EXCESSIVE PEDAL
EFFORT1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist
(vacuum leak).2. Refer to power brake booster
diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
5 - 6 BRAKES - BASERS
BRAKES - BASE (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)1. One of the two hydraulic circuits
to the front brakes is malfunctioning.1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles).2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist.3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N1. Brake lamp switch out of
adjustment.1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment.1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
RSBRAKES - BASE5-7
BRAKES - BASE (Continued)
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(6) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
ABS ICU Mounting Bolts To
Bracket11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts28 21 250
ABS CAB-To-HCU Mounting
Screws2Ð17
ABS Wheel Speed Sensor
Head Mounting Bolt - Front13 Ð 115
ABS Wheel Speed Sensor
Head Mounting Bolt - Rear10 Ð 90
Adjustable Pedal Position
Sensor Mounting Screws7.5 66 Ð
Adjustable Pedal Module
Mounting Screws2.0 15 Ð
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt47 35 Ð
Disc Brake Caliper Guide
Pin Bolts35 26 Ð
Disc Brake Caliper Bleeder
Screw15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw10 Ð 80
Drum Brake Support Plate
Mounting Bolts130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts28 21 250
Master Cylinder Mounting
Nuts25 19 225
Power Brake Booster
Mounting Nuts28 21 250
Proportioning Valve
Mounting Bolts54 40 Ð
Proportioning Valve Axle
Bracket Mounting Bolt20 Ð 175
Parking Brake Lever (Pedal)
Mounting Bolts And Nut28 21 250
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
BASE BRAKE SYSTEM
Fig. 3 TOOL 6921 INSTALLED ON MASTER
CYLINDER
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
Tubes, Master Cylinder Bleeding 6920
RSBRAKES - BASE5-9
BRAKES - BASE (Continued)
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ADJUSTABLE PEDAL SWITCH
DESCRIPTION
The adjustable pedal switch is mounted on the left
side of the lower steering column shroud (Fig. 5). The
adjustable pedal switch adjusts the adjustable pedal
assembly fore-and-aft. The pedal assembly moves in
the direction the switch is actuated.
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SWITCH
Refer to Appropriate Diagnostic Information.
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) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 6).
(4) Disconnect parking brake release link at
release handle.
(5) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.
(6) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 6).
(7) Remove screws fastening upper and lower
steering column shrouds to steering column (Fig. 7).
(8) Remove the lower shroud with adjustable pedal
switch; disconnect switch wiring connector along left
side of column as shroud is removed (Fig. 8).
Fig. 4 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. 5 Adjustable Pedal Switch Location
1 - ADJUSTABLE PEDAL SWITCH
2 - LOWER STEERING COLUMN SHROUD
Fig. 6 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
RSBRAKES - BASE5-11
BRAKE FLUID LEVEL SWITCH (Continued)
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(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.
MASTER CYLINDER
DESCRIPTION
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 54). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
For information on master cylinder application,
bore and type, view the following table:
BRAKE SYSTEMMASTER CYLINDER
BORE/TYPE
Disc/Drum - ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Drum - Non-ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Disc - ABS27.0 mm (1-1/16 in.)
Conventional
Compensating Port
Disc/Disc ABS With
Traction Control27.0 mm (1-1/16 in.) Dual
Center Port
CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections.
The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir.
The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
Fig. 54 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RSBRAKES - BASE5-37
JUNCTION BLOCK (Continued)
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CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 55). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly.
The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358.
(2) Attach special tools for bleeding master cylin-
der in the following fashion:
(a)For non-traction control equipped mas-
ter cylinders, thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 56).
(b)For traction control equipped master
cylinders, thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 56).
Fig. 55 RHD MASTER CYLINDER AND POWER
BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
Fig. 56 Master Cylinder Set Up For Bleeding
1 - BLEEDER TUBES 8358
2 - WOODEN DOWEL
3 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL
EQUIPPED MASTER CYLINDERS)
4 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL
EQUIPPED MASTER CYLINDERS)
5 - 38 BRAKES - BASERS
MASTER CYLINDER (Continued)
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