wheel CHRYSLER VOYAGER 1996 Repair Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 1996, Model line: VOYAGER, Model: CHRYSLER VOYAGER 1996Pages: 1938, PDF Size: 55.84 MB
Page 115 of 1938
(5) Install the outboard brake shoe on the disc
brake 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. 56)
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 22 N´m (192 in. lbs.).
(8) Install the wheel and tire assembly.
(9) 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.).
(10) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
REAR BRAKE DRUM
REMOVE
(1) Remove the tire and wheel assembly from the
vehicle
Remove the park brake cable, for the wheel of the
vehicle that is being worked on, from the park brakecable equalizer (Fig. 60). This is required to gain
access to the star wheel. If the cable is not removed
from the equalizer, the cable and spring inside of the
brake drum is in the way of the star wheel.
(2) Remove the rear brake shoe adjusting hole
cover plug.
(3) Insert a thin screwdriver into brake adjusting
hole and hold adjusting lever away from notches of
adjusting screw star wheel.
(4) Insert Tool C-3784 into brake adjusting hole
and engage notches of brake adjusting screw star
wheel. Release brake adjustment by prying down
with adjusting tool.
(5) Remove rear brake drum from rear hub/bear-
ing assembly.
INSTALL
(1) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(2) Install the rear brake drums on the hubs.
(3) Adjust rear brake shoes per Adjusting Rear
Brakes procedure in the service adjustments section
of the service manual.
(4) Install the removed park brake cable back on
the park brake cable equalizer (Fig. 60)
(5) Install wheel and tire.
(6) 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 130 N´m (95 ft. lbs.).
Fig. 59 Installing Inboard Brake Shoe
Fig. 60 Park Brake Cable Equlizer
NSBRAKES 5 - 33
REMOVAL AND INSTALLATION (Continued)
Page 116 of 1938
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)
Page 119 of 1938
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 66). 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. 66) attaching the
upper return spring to the automatic adjuster assem-
bly.
(8) Install the brake shoe to brake shoe lower
return springs on the brake shoes (Fig. 64) and (Fig.
65).
(9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 63).
(10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 62).
(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 per Adjusting Rear
Brakes procedure in the service adjustments section
of the service manual.
(16) Install the wheel and tire assembly.
(17) Push the park brake pedal to the floor once
and release pedal. This will automatically remove the
slack from and correctly adjust the park brake
cables.
(18) 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 130 N´m (95 ft. lbs.).
(19) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
BRAKE SUPPORT PLATE (REAR DRUM BRAKES)
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual for required lifting procedure.
(2) Remove wheel and tire.
(3) Remove brake drum from hub/bearing.
(4) Remove brake shoes from brake support plate.
Refer to Rear Brake Shoe Removal in the removal
and installation section in this group of the service
manual for the required procedure.(5) Disconnect the park brake cable from the park
brake actuation lever.
(6) Remove the rear wheel speed sensor from the
rear hub/bearing flange (Fig. 74). This will prevent
damage to the speed sensor during removal and
installation of the hub/bearing.The rear wheel
speed sensor bolts to the hub/bearing. It can
not be removed unless the speed sensor is
removed first.
CAUTION: When working in the area of the rear
hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone
wheel are not damaged. Damage to the teeth on the
tone wheel will result in false ABS cycling and cor-
rosion of the tone wheel.
(7) Remove the 4 bolts (Fig. 75) attaching the hub/
bearing to the flange of the rear axle .
Fig. 74 Rear Wheel Speed Sensor
Fig. 75 Rear Hub/Bearing Mounting Bolts
NSBRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)
Page 120 of 1938
CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.
(8) If hub/bearing cannot be removed from the axle
by hand, use Remover Special Tool 8214 (Fig. 76) and
following procedure to press the hub/bearing out of
the axle.
(a) Place Special Tool 8214-1 over tone wheel
and against cast flange of hub/bearing (Fig. 76)
(b) Put a dab of grease in the bolt pilot hole on
the back of Special Tool 8214-1.
(c) Insert Special Tool 8214-2 into the hole in the
bottom of the end casting on the axle (Fig. 76).
Special Tool 8214-2 should be against and sup-
ported by the axle plate (Fig. 76) when pressing
the wheel bearing out of the axle.If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
(d) Align bolt in Special Tool 8214-2 with pilot
hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1.
(e) Press hub/bearing out of axle by continuing
to tighten bolt in Special Tool 8214-2 against Spe-
cial Tool 8214-1.
(9) Remove the hub/bearing from the rear axle and
brake support plate (Fig. 77).
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 78) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate.(11) Lower vehicle enough to access the brake
pedal.
(12) Using a brake pedal depressor, move brake
pedal to a position past its first 1 inch of travel. This
will prevent brake fluid from draining out of master
cylinder when brake tube is remove from wheel cyl-
inder.
(13) Raise vehicle.
(14) Disconnect brake tube from wheel cylinder
(Fig. 79).
(15) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate (Fig. 79).
(16) Remove the wheel cylinder from the brake
support plate.
(17) Remove the rear brake support plate from the
rear axle.
Fig. 76 Special Tool 8214 Installed
Fig. 77 Hub/Bearing Removal And Installation On
Axle
Fig. 78 Removing Park Brake Cable From Brake
Support Plate
5 - 38 BRAKESNS
REMOVAL AND INSTALLATION (Continued)
Page 121 of 1938
INSTALL
(1) Install the 4 hub/bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 80).
NOTE: When installing the hub/bearing on the rear
axle, the bearing is to be installed with the thick
bearing mounting flange (Fig. 77) pointing down.
(3) Align the rear hub/bearing with the 4 mount-
ing bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and
squarely seated onto flange of rear axle.
(4) Tighten the 4 hub/bearing mounting bolts (Fig.
75) to a torque of 129 N´m (95 ft. lbs.)(5) Apply sealant such as Mopar Gasket-In-A-Tube
or an equivalent around the wheel cylinder opening
in the brake support plate.
(6) Install wheel cylinder onto brake support and
tighten the wheel cylinder to brake support plate
attaching bolts (Fig. 79) to 8 N´m (75 in. lbs.).
(7) Install brake tube (Fig. 79) on rear wheel cyl-
inder. Tighten tube nut to a torque of 16 N´m (142 in.
lbs.).
(8) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 74). Install the speed sensor
attaching bolt and tighten to a torque of 12 N´m (105
in. lbs.).
(9) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(10) Install the park brake cable on the park brake
actuation lever.
(11) Install the rear brake shoes on the brake sup-
port plate. Refer to Brake Shoe Service in this sec-
tion of the service manual for the proper brake shoe
installation procedure.
(12) Install brake drum onto hub/bearing.
(13) Install wheel and tire.
(14) Tighten wheel stud nuts to 129 N´m (95 ft.
lbs.).
(15) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
(16) Bleed the entire brake system. See Bleeding
Brake System in the Service Procedures section in
this group of the service manual.
REAR BRAKE WHEEL CYLINDER
REMOVE
(1) In case of a leak, remove brake shoes, (replace
if soaked with grease or brake fluid.)
(2) Disconnect the rear brake hydraulic tube from
the wheel cylinder (Fig. 81).
Fig. 79 Rear Wheel Cylinder Mounting Bolts And
Brake Tube
Fig. 80 Brake Support Plate Mounted On Bearing
Attaching Bolts
Fig. 81 Brake Hydraulic Tube At Wheel Cylinder
NSBRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)
Page 122 of 1938
(3) Remove the rear wheel cylinder attaching bolts
(Fig. 81). Then pull wheel cylinder assembly off the
brake support plate.
INSTALL
(1) Apply MopartGasket In-A-Tube or equivalent
sealant around wheel cylinder mounting surface in
brake support plate.
(2) Install wheel cylinder onto brake support, and
tighten the wheel cylinder to brake support plate
attaching bolts (Fig. 81) to 8 N´m (75 in. lbs.).
(3) Attach hydraulic brake tube to wheel cylinder,
(Fig. 81) and tighten tube to wheel cylinder fitting to
16 N´m (142 in. lbs.).
(4) Install brake shoes on support plate.
(5) Install rear brake drum onto rear hub. Install
rear wheel and tire assembly, tighten wheel stud
nuts to 129 N´m (95 ft. lbs.).
(6) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
(7) Bleed the entire brake system. See (Bleeding
Brake System) in Service Adjustments section in this
group of the service manual.
HUB/BEARING
FRONT WHEEL DRIVE
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual for required lifting procedure.
(2) Remove wheel and tire.
(3) Remove brake drum from hub/bearing.
(4) Remove rear wheel speed sensor from rear hub/
bearing (Fig. 82). This will prevent damage to the
speed sensor during removal and installation of the
hub/bearing.The rear wheel speed sensor bolts
to the hub/bearing. It can not be removed
unless the speed sensor is removed first.
CAUTION: When working in the area of the rear
hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone
wheel are not damaged. Damage to the teeth on the
tone wheel will result in false ABS cycling and cor-
rosion of the tone wheel.
(5) Remove the 4 bolts (Fig. 83) attaching the hub/
bearing to the rear axle.
CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling onit by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.
(6) If hub/bearing cannot be removed from the axle
by hand, use Remover Special Tool 8214 (Fig. 84) and
following procedure to press the hub/bearing out of
the axle.
(a) Place Special Tool 8214-1 over tone wheel
and against cast flange of hub/bearing (Fig. 84)
(b) Put a dab of grease in the bolt pilot hole on
the back of Special Tool 8214-1.
(c) Insert Special Tool 8214-2 into the hole in the
bottom of the end casting on the axle (Fig. 84).
Special Tool 8214-2 should be against and sup-
ported by the axle plate (Fig. 84) when pressing
the wheel bearing out of the axle.If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
Fig. 82 Rear Wheel Speed Sensor
Fig. 83 Rear Hub/Bearing Mounting Bolts
5 - 40 BRAKESNS
REMOVAL AND INSTALLATION (Continued)
Page 123 of 1938
(d) Align bolt in Special Tool 8214-2 with pilot
hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1.
(e) Press hub/bearing out of axle by continuing
to tighten bolt in Special Tool 8214-2 against Spe-
cial Tool 8214-1.
(7) Remove the hub/bearing from the rear axle and
brake support plate (Fig. 85).
INSTALL
(1) Install the 4 hub/bearing to axle mounting
bolts into the holes in the flange of the rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.
(3) Align the rear hub/bearing with the 4 mount-
ing bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and
squarely seated onto flange of rear axle.
(4) Tighten the 4 hub/bearing mounting bolts (Fig.
83) to a torque of 129 N´m (95 ft. lbs.)(5) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 82). Install the speed sensor
attaching bolt and tighten to a torque of 12 N´m (105
in. lbs.).
(6) Install brake drum on hub/bearing.
(7) Install wheel and tire.
(8) Tighten the wheel stud nuts in the proper
sequence to a torque of 129 N´m (95 ft. lbs.).
(9) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
ALL WHEEL DRIVE
REMOVE
(1) Set the parking brake.The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(3) Remove the wheel/tire.
(4) Remove the cotter pin and nut retainer (Fig.
86) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 87) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 88) from
the stub shaft of the outer C/V joint.
(7) Remove the 6 bolts (Fig. 89) mounting the
driveshaft inner joint to the output shaft of the rear
drive line module.
(8) Remove the rear wheel speed sensor (Fig. 90)
from the rear hub/bearing.
(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter
guide pin bolts (Fig. 91).
(11) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
Fig. 84 Special Tool 8214 Installed
Fig. 85 Removing Rear Hub/Bearing From Axle
Fig. 86 Cotter Pin And Nut Retainer
NSBRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)
Page 124 of 1938
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. 92).(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
93).
(13) Remove the rotor from the hub/bearing.
Fig. 87 Spring Washer
Fig. 88 Hub Nut And Washer
Fig. 89 Driveshaft Attachment To Driveline Module
Fig. 90 Wheel Speed Sensor
Fig. 91 Caliper Guide Pin Bolts
Fig. 92 Removing / Installing Caliper
5 - 42 BRAKESNS
REMOVAL AND INSTALLATION (Continued)
Page 126 of 1938
caliper adapter and hub/bearing are squarely seated
against the axle. Then tighten the hub/bearing
mounting bolts to a torque of 129 N´m (95 ft. lbs.).
(3) Install driveshaft in hub/bearing and on output
shaft of rear drive line module. Driveshaft is
installed by first sliding the outer joint of the drive-
shaft into the hub/bearing and then compressing the
inner joint on the driveshaft and installing it on the
output shaft the drive line module.
(4) Install rotor on hub/bearing.
(5) Carefully lower disc brake caliper and brake
shoes over rotor and onto caliper adapter by revers-
ing the removal procedure (Fig. 92).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(6) Install the disc brake caliper guide pin bolts
(Fig. 91). Tighten the guide pin bolts to a torque of
22 N´m (192 in. lbs.).
(7) Clean all foreign material off the threads of the
outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 88) on the stub shaft of the outer C/V
joint.
(8) Lower vehicle.
(9) Set the park brake.This is required to keep
the driveshaft from rotating when tightening
and torquing the hub nut and driveshaft inner
joint to driveline module mounting nuts.
(10) Raise vehicle.
(11) Tighten the driveshaft inner joint to drive line
module output shaft mounting bolts (Fig. 89) to a
torque of 61 N´m (45 ft. lbs.).
(12) Tighten the outer C/V joint hub nut (Fig. 88)
to a torque of 244 N´m (180 ft. lbs.).
(13) Install the spring washer (Fig. 87) on the stub
shaft of the outer C/V joint.
(14) Install the nut retainer and cotter pin (Fig.
86) on the stub shaft of the outer C/V joint.
(15) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 90). Tighten the wheel speed sen-
sor attaching bolt to a torque of 12 N´m (105 in. lbs).
(16) Install wheel and tire.
(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 129 N´m (95 ft. lbs.).
(18) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(19) Road test vehicle to ensure proper operation
of the brake system.MASTER CYLINDER
CAUTION: Different types of master cylinders are
used on this vehicle. Vehicles equipped with trac-
tion control use a center port master cylinder. Vehi-
cles not equipped with traction control use a
compensating port master cylinder. Be sure to ver-
ify if the vehicle is equipped with traction control
and that the correct replacement master cylinder is
used. Also, vehicles that are equipped with four
wheel disc brakes have a master with a different
size piston bore than the other master cylinders. If
a new master cylinder is being installed, be sure
the correct master cylinder is used for the type of
brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle's engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
CAUTION: Before removing the master cylinder
filler tube from the brake fluid reservoir, the filler
tube, brake fluid reservoir and master cylinder must
be thoroughly cleaned. This must be done to pre-
vent dirt particles from falling into the brake fluid
reservoir and entering the brakes hydraulic system.
(2) Thoroughly clean all surfaces of the filler neck,
brake fluid reservoir, and master cylinder. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent.
(3) Remove master cylinder filler tube from brake
fluid reservoir by pushing down and rotating (Fig.
97). Then remove the cap from the removed filler
tube and install it on the master cylinder reservoir.
(4) Remove vehicle wiring harness connector, from
the brake fluid level sensor, in master cylinder brake
fluid reservoir (Fig. 98).
(5) Disconnect the primary and secondary brake
tubes from the master cylinder housing (Fig. 99).
Install sealing plugs in the open brake tube outlets
on master cylinder assembly.
5 - 44 BRAKESNS
REMOVAL AND INSTALLATION (Continued)
Page 142 of 1938
(23) Install the negative (ground) cable on the bat-
tery.
(24) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
On this vehicle, the park brake shoes are removed
from the disc brake adapter with the disc brake
adapter removed from the vehicle.
REMOVE
(1) Set the parking brake.The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(3) Remove the wheel/tire.
(4) Remove the cotter pin and nut retainer (Fig.
139) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 140) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 141)
from the stub shaft of the outer C/V joint.
(7) Release the parking brake.
(8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 142).
(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 143).
(10) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliperand the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 144).
(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
Fig. 139 Cotter Pin And Nut Retainer
Fig. 140 Spring Washer
Fig. 141 Hub Nut And Washer
Fig. 142 Locking Out Automatic Adjuster
5 - 60 BRAKESNS
REMOVAL AND INSTALLATION (Continued)