tow CHRYSLER VOYAGER 1996 Owner's Manual

NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
²Left Rear Wheel
²Right Front Wheel
²Right Rear Wheel
²Left Front Wheel
(4) Open the left rear wheel bleeder screw at least
one full turnor more to obtain an adequate flow of
brake fluid (Fig. 29).
CAUTION: Just cracking the bleeder screw often
restricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
(5) After 4 to 8 ounces of brake fluid has been bled
through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate agood bleed of the hydraulic system has been
obtained.
(6) Repeat the procedure at all the other remain-
ing bleeder screws. Then check the pedal for 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 and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
BLEEDING WITHOUT A PRESSURE BLEEDER
NOTE: Correct manual bleeding of the brakes
hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the
manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of
the brake hydraulic system, correctly adjust the
rear brakes.
NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
²Left Rear Wheel
²Right Front Wheel
²Right Rear Wheel
²Left Front Wheel
(1) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened.
(2) Push the brake pedal toward the floor and hold
it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens the
brake pedal will drop all the way to the floor.
(3) Release the brake pedal onlyafterthe bleeder
screw is closed.
(4) Repeat steps 1 through 3, four or five times, at
each bleeder screw in the required sequence. This
should pass a sufficient amount of fluid to expel all
the trapped air from the brake system. Be sure to
monitor the fluid level in the master cylinder, so it
stays at a proper level so air will not enter the brake
system through the master cylinder.
(5) Perform a final adjustment of the rear brake
shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.Fig. 28 Pressure Bleeding Cap Installed On Master
Cylinder
Fig. 29 Rear Wheel Cylinder Bleeder Screw
NSBRAKES 5 - 21
SERVICE PROCEDURES (Continued)

(4) Remove the locking pliers from the front park
brake cable. This will allow the adjuster in the park
brake pedal mechanism to rotate around to its stop.
This will remove the tension from the adjuster and
front park brake cable.
Use the following procedure to reset the auto
adjuster in the park brake pedal mechanism.
(5) Grasp the exposed section of the front park
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 42).
(6) Install the equalizer on the front park brake
cable.
(7) Install the left rear and intermediate park
brake cable in the correct location on the park brake
cable equalizer (Fig. 43).
(8) Remove the locking pliers from the front park
brake cable. This will allow the adjuster in the park
brake pedal mechanism to tension the park brake
cables.
(9) Apply and release the park brake pedal one
time. This will seat the park brake cables and allow
the auto adjuster in the park brake pedal mechanism
to correctly tension the park brake cables.
REMOVAL AND INSTALLATION
WHEEL AND TIRE INSTALLATION
To install the wheel and tire assembly, first posi-
tion it properly on the mounting surface using the
hub pilot as a guide. Then progressively tighten thelug nuts in the proper sequence to half of the
required torque. Finally tighten the lug nuts in the
proper sequence to 129 N´m (95 ft. lbs.). Never use
oil or grease on studs or nuts.
FRONT DISC BRAKE CALIPER
SERVICE PRECAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER±DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
drum and external surfaces of hub/bearing assem-
bly.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance group of this service manual.
(2) Remove front wheel and tire assemblies.
Fig. 43 Park Brake Cable Attachment To Equalizer
NSBRAKES 5 - 27
SERVICE PROCEDURES (Continued)

(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoe linings.
FRONT DISC BRAKE PADS
REMOVE
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTERMARKET BRAKE
LININGS MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER±DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
drum and external surfaces of hub/bearing assem-
bly.
(1) Remove outboard brake pad, by prying the pad
retaining clip over raised area on caliper (Fig. 50).
Then slide the pad down and off the caliper.
(2) Pull inboard brake pad away from piston, until
retaining clip on brake pad is free from cavity in cal-
iper piston (Fig. 51).
INSTALL
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly. This is required for cal-
iper installation with new brake pad assemblies.
(2) Remove the protective paper from the noise
suppression gasket on both the inner and outer brake
pad assemblies (if equipped).
NOTE: The inboard and outboard brake pads are
not common, refer to (Fig. 52) for inboard and out-
board brake pad assembly identification.
(3) Install the new inboard brake pad assembly
into the caliper piston by firmly pressing into piston
bore (Fig. 53). Be sure inboard brake pad assembly is
positioned squarely against face of caliper piston.
(4) Slide the new outboard brake pad assembly
onto the caliper assembly (Fig. 54).
Fig. 50 Removing Outboard Brake Pad From Caliper
Fig. 51 Removing Inboard Brake Pad From Piston
5 - 30 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

REAR DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOSFREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
During service procedures, grease or any other for-
eign material must be kept off brake shoe assem-
blies, and braking surfaces of brake drum and
external surfaces of hub/bearing assembly.
Handling of the braking disc and caliper is to be
done in such a way as to avoid deformation of the
disc and scratching or nicking of brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, itMUSTbe
replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 55).
(4) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate rear of caliper up from
the adapter. Then pull the front of the caliper and
the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 56).
(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
57).
Fig. 52 Front Brake Pad Assembly Identification
Fig. 53 Installing Inboard Brake Pad Assembly
Fig. 54 Installing Outboard Brake Shoe Assembly
NSBRAKES 5 - 31
REMOVAL AND INSTALLATION (Continued)

REAR DRUM BRAKE SHOES
REMOVE
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTERMARKET BRAK-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER±DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKE LINING DUST BY SANDING BRAKE
LININGS WHEN SERVICING A VEHICLE. DISPOSE
OF ALL DUST AND DIRT SUSPECTED OF CONTAIN-
ING ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL
RECOMMENDED SAFETY PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION (OSHA) AND THE ENVI-
RONMENTAL PROTECTION AGENCY (EPA), FOR
HANDLING AND DISPOSAL OF PRODUCTS CON-
TAINING ASBESTOS.
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining nuts
(if equipped). Then remove rear brake drums from
hub and bearing assemblies.
NOTE: When creating slack in the park brake
cables by locking out the automatic adjuster, (Fig.
61) 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. 61)
(5) Remove adjustment lever spring (Fig. 62) from
adjustment lever and front brake shoe.(6) Remove adjustment lever (Fig. 63) from leading
brake shoe.
Fig. 61 Locked Out Park Brake Automatic Adjuster
Fig. 62 Adjustment Lever Actuating Spring
Fig. 63 Adjustment Lever
5 - 34 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

drain hose (Fig. 107) from wiper module. Remove the
2 nuts attaching the master cylinder to the vacuum
booster (Fig. 107).
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(11) Remove the master cylinder and brake tubes
as an assembly from the vacuum booster. When mas-
ter cylinder is removed, lay it out of the way on top
of the left motor mount
(12) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(13) Locate the vacuum booster input rod to brake
pedal attachment under instrument panel. Position a
small screwdriver between the center tang on the
vacuum booster input rod to brake pedal pin retain-
ing clip (Fig. 108).(14) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assembled.
(15) Remove the 4 nuts attaching the vacuum
booster to the dash panel. Nuts are accessible from
under dash panel in area of the steering column and
pedal bracket assembly.
(16) From outside the vehicle, slide vacuum
booster forward until its mounting studs clear dash
panel. Then tilt the booster up and toward the center
of vehicle to remove.
CAUTION: Do not attempt to disassemble the vac-
uum booster it is to be serviced ONLY as a com-
plete assembly.
INSTALL
CAUTION: When installing the vacuum booster in
the vehicle be sure the heater hoses do not become
trapped between the booster and the dash panel of
the vehicle.
(1) Position vacuum booster onto dash panel using
the reverse procedure for its removal.
(2) Install the 4 mounting nuts for the vacuum
booster. Tighten the 4 mounting nuts to a torque of
29 N´m (250 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the vac-
uum booster input rod.
CAUTION: When installing the brake pedal pin on
the vacuum booster input rod, do not re-use the old
retaining clip.
(4) Connect the vacuum booster input rod on the
brake pedal pin and install aNEWretaining clip
(Fig. 109).
(5) Connect the vacuum hose on the check valve in
the vacuum booster.
CAUTION: The master cylinder is used to create
the seal for holding vacuum in the vacuum booster.
The vacuum seal on the master cylinder MUST be
replaced with a NEW seal whenever the master cyl-
inder is removed from the vacuum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(6) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
Fig. 107 Master Cylinder Attachment To Vacuum
Booster
Fig. 108 Input Rod Retaining Pin
5 - 48 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Position power brake booster onto dash panel
using the reverse procedure for its removal.
(2) Install the 4 power brake vacuum booster
mounting nuts. Tighten the 4 mounting nuts to a
torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the
brake vacuum booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) Connect power brake vacuum booster input rod
on the brake pedal pin and install aNEWretaining
clip (Fig. 116).
(5) Connect the vacuum hose on the check valve in
the power brake vacuum booster.
CAUTION: The master cylinder is used to create
the seal for holding vacuum in the power brake vac-
uum booster. The vacuum seal on the master cylin-
der MUST be replaced with a NEW seal whenever
the master cylinder is removed from the power
brake vacuum booster.CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(6) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(7) Install aNEWvacuum seal on mounting flange
of master cylinder assembly (Fig. 117).
(8) Position master cylinder on studs of power
brake booster, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(9) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 114). Tighten both mount-
ing nuts to a torque of 25 N´m (225 in. lbs.).
(10) Install the wiper module drain hose (Fig. 114)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
Fig. 115 Booster Input Rod Retaining PinFig. 116 Retaining Pin Installed On Brake Pedal Pin
Fig. 117 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 51
REMOVAL AND INSTALLATION (Continued)

(15) Remove the EGR Valve and the vacuum
transducer (Fig. 125) as an assembly from the intake
manifold.
(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Locate the vacuum booster input rod to brake
pedal connection under the instrument panel. Posi-
tion a small screwdriver between the center tang on
the power brake booster input rod to brake pedal pin
retaining clip (Fig. 126).
(18) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(19) Remove the 4 nuts attaching the power brake
vacuum booster to the dash panel. Nuts are accessi-ble from under dash panel in area of the steering col-
umn and pedal bracket assembly.
(20) From outside the vehicle, slide power brake
vacuum booster forward until its mounting studs
clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Position vacuum booster on dash panel using
the reverse procedure of its removal.
(2) Install the 4 nuts mounting the vacuum
booster to the dash panel. Tighten the 4 mounting
nuts to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the vac-
uum booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) Install vacuum booster input rod on brake
pedal pin and install aNEWretaining clip (Fig. 127).
(5) Connect the vacuum hose on the check valve in
the power brake vacuum booster.
(6) Install EGR Valve and vacuum transducer (Fig.
125) on the intake manifold. Install and tighten the 2
EGR valve mounting bolts to a torque of 22 N´m (200
in. lbs.).
Fig. 125 EGR Valve Attachment To Intake Manifold
Fig. 126 Vacuum Booster Input Rod Retaining Pin
Fig. 127 Retaining Pin Installed On Brake Pedal Pin
5 - 54 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(6) Install the hold down spring and pin (Fig. 153)
on the leading park brake shoe.
(7) Install the lower return spring (Fig. 152) on
the leading and trailing park brake shoes.When
installing the hold down spring it is to be
installed behind the park brake shoes (Fig.
152).
(8) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle.
(9) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 158).
(10) Install the hub/bearing on the stub shaft of
outer C/V joint and into the end of the axle. (Fig.
150).
(11) In a progressive criss-cross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.).
(12) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 148). Tighten the wheel speed
sensor attaching bolt to a torque of 12 N´m (105 in.
lbs).
(13) Install the park brake cable into its mounting
hole in the adapter.Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter.
(14) Install the end of the park brake cable on the
park brake actuator lever (Fig. 146).
NOTE: The horseshoe clip must be installed and
installed properly when the park brake cable isinstalled in the adapter. The purpose of the horse-
shoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not
installed the park brake cable retainer will rattle in
the adapter.
(15) Install aNEWhorseshoe clip on the park
brake cable retainer (Fig. 146). The horseshoe clip is
installed between the retainer for the park brake
cable and the adapter. Horseshoe clip must be
installed with the curved end of the clip pointing
straight up and the edge of the curved end facing
toward the rear of the vehicle (Fig. 146).
(16) Remove the locking pliers (Fig. 142) from the
front park brake cable.
(17) Adjust the park brake drum-in-hat brake
shoes. See Park Brake Shoe Adjustment in the
adjustment section in this group of the service man-
ual for the proper park brake shoe adjustment proce-
dure.
(18) Install the rotor on the hub/bearing.
(19) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 144).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(20) Install the caliper guide pin bolts (Fig. 143).
Tighten the guide pin bolts to a torque of 22 N´m
(192 in. lbs.).
(21) Clean all foreign material off the threads of
the outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 141) on the stub shaft of the outer C/V
joint.
(22) Set the parking brake.
(23) Tighten the hub nut to a torque of 244 N´m
(180 ft. lbs.).
(24) Install the spring washer (Fig. 140) on the
stub shaft of the outer C/V joint.
(25) Install the nut retainer and cotter pin (Fig.
139) on the stub shaft of the outer C/V joint.
(26) Install the wheel and tire assembly.
(27) 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 129 N´m (95 ft. lbs.).
(28) Remove jackstands or lower hoist.
(29)Fully apply and release the park brake
pedal one time. This will seat and correctly
adjust the park brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
Fig. 158 Adapter Installed On Mounting Bolts
5 - 64 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

group of the service manual for the installation pro-
cedure.
(13) Install wheel and tire.
(14) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(15) Lower vehicle.
(16) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(17) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
PARK BRAKE CABLE ADJUSTMENT
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. See Rear Brake Adjust-
ment and Park Brake Shoe Adjustment in the Ser-
vice Adjustments Section in this group of the service
manual.
When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes.
When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
PROPORTIONING VALVE (HEIGHT SENSING)
Proportioning valve actuator adjustment will be
required if there is a complaint of premature rear
wheel lockup and the front and rear brake shoe lin-
ings checked OK during inspection, the height sens-
ing proportioning valve required replacement, or
there is a complaint of excessive pedal effort and the
vacuum booster and brake pedal checked OK. Make
sure the proportioning valve and the mounting
bracket are firmly attached to the vehicle. Then, pro-
ceed with the following procedure to perform the
adjustment of the actuator.(1) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or with a frame contact type
hoist so the rear suspension of the vehicle is hanging
free. See hoisting in the Lubrication And Mainte-
nance section of this service manual.
(2) Remove rear wheels/tires.
(3) Using an appropriate jack, support the rear
axle prior to the removal of the track bar and shock
absorber bolts from the rear axle.
(4) Unbolt the track bar from the rear axle.
(5) Unbolt both shock absorbers from the rear
axle.
(6) Loosen (do not remove) both of the leaf spring
to front spring hanger pivot bolts.
NOTE: When lowering the rear axle be sure that the
leaf springs do not come in contact with the hoist
limiting the downward movement of the axle. If this
occurs an improper adjustment of the actuator may
result.
(7) Lower the rear axle so it is at its farthest point
of downward movement.
(8) Loosen the adjustment nut (Fig. 203) on the
actuator.
(9) Be sure the hooked end of the actuator is cor-
rectly (fully) seated in the clip on the proportioning
valve lever and that the clip is correctly positioned
on the lever of the proportioning valve.
(10) Pull the housing of the proportioning valve
actuator toward the spring hanger (Fig. 203) until
the lever on the proportioning valve bottoms on the
body of the proportioning valve.Hold the propor-
tioning valve actuator in this position while
tightening the adjustment nut (Fig. 203) to a
torque of 5 N´m (45 in. lbs.). Proportioning
valve adjustment is now complete.
(11) Install shock absorbers and track bar on rear
axle.Do not tighten the mounting bolts for any
of the loosened suspension components at this
time.
(12) Install the wheel/tires.
Fig. 203 Proportioning Valve Actuator Adjustment
NSBRAKES 5 - 81
ADJUSTMENTS (Continued)