steering CHRYSLER VOYAGER 2001 Repair Manual

(7) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut damper to
steering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N´m (60 ft. lbs.) plus an additional
1/4 turn.
(8) Install tie rod end into steering knuckle. Start
attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a socket, (Fig. 6)
tighten tie rod end to steering knuckle attaching nut.
Then using a crowfoot and socket (Fig. 13), tighten
the tie rod end attaching nut to a torque of 75 N´m
(55 ft. lbs.).
(9) Install braking disc on hub and bearing assem-
bly.
(10) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper assembly under abutment on steering
knuckle, and then rotating top of caliper against top
abutment.
(11) Install disc brake caliper adapter to steering
knuckle attaching bolts (Fig. 4). Tighten the disc
brake caliper adapter attaching bolts to a torque of
169 N´m (125 ft. lbs.).(12) Clean all foreign matter from the threads of
the outer CV joint. Install the washer and half shaft
to hub/bearing assembly nut on half shaft and
securely tighten nut.
(13) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N´m (100
ft. lbs.).
(14) Lower vehicle.
(15) With the vehicle's brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N´m (180 ft. lbs.) (Fig. 14).
(16) Install the spring wave washer on the end of
the half shaft.
(17) Install the hub nut lock, and anewcotter pin
(Fig. 2). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 2).
(18) Check for correct fluid level in transaxle
assembly. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
(19) Set front toe on vehicle to required specifica-
tion.
Fig. 13 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCHFig. 14 Torquing Front Half Shaft To Hub Nut
1 - TORQUE WRENCH
3 - 6 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)

(11) Install the half shaft requiring boot replace-
ment back on the vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT -
INSTALLATION)
OUTER CV JOINT BEARING
SHIELD
REMOVAL
(1) Clamp half shaft in a vise by the interconnect-
ing shaft.
(2) Using a drift (Fig. 38) tap around the entire
edge of the bearing shield until it is removed from
the outer CV joint.
INSTALLATION
(1) Install bearing shield by hand on outer CV
Joint so that it is installed squarely on the CV joint.
(2) Position installer, Special Tool C-4698-2, and
handle, Special Tool C-4698-1, on face of bearing
shield (Fig. 39).
CAUTION: If bearing shield is not installed flush
against the face of the outer CV joint, interference
with steering knuckle will occur when driveshaft is
installed.
Fig. 37 Sealing Boot Retaining Clamp Installed -
Typical
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975A
4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
Fig. 38 Removing Bearing Shield from Outer CV
Joint
1 - DRIFT
2 - OUTER CV JOINT
3 - BEARING SHIELD
Fig. 39 Special Tools for Installing Bearing Shield
1 - SPECIAL TOOL C-4698-2
2 - SPECIAL TOOL C-4698-1
3 - BEARING SHIELD
4 - OUTER CV JOINT
3 - 14 HALF SHAFT - FRONTRS
CV BOOT - OUTER (Continued)

The two different brake calipers use different
devices to control rattling. While the TRW brakes use
spring clips that mount at the ends of the shoes in
the adapters, Continental Teves brakes use a clip on
the rear of the inboard pad to hold it to the piston
and a larger clip on the outside of the caliper, holding
it to the adapter (Fig. 7).
All brake caliper adapters mount to the steering
knuckle in the same way using two mounting bolts.
The brake rotors are also different depending on
brake system. The TRW (disc/drum) front brakes uti-
lize an inverted-hat style rotor. This rotor is exter-
nally vented meaning the inner most diameter of the
braking disc vents to the outboard side (or face) of
the rotor (Fig. 8). The Continental Teves (disc/disc)
front brakes utilize the familiar internally-vented hat
style rotor. Internally-vented refers to the fact that
the inner most diameter of the braking disc vents to
the inboard side of the rotor (Fig. 8).
CAUTION: TRW and Continental Teves brake rotors
are not interchangeable. If brake rotors are inter-
changed, noise and wear problems can result.
DESCRIPTION - DISC BRAKES (REAR)
There are several distinctive features to the rear
disc brakes on this vehicle (Fig. 9). The single piston,
floating caliper rear disc brake system includes a hub
and bearing assembly, adapter, rotor, caliper, and
brake shoes.
This vehicle is equipped with a caliper having a 42
mm (1.65 in.) piston and uses a 15 inch solid non-
vented brake rotor. The brake rotor is described as adrum-in-hat style because of its dual role as a brak-
ing disc and parking brake drum.
The parking brake system on vehicles equipped
with rear disc brakes consists of a small duo-servo
drum brake mounted to the caliper adapter and uses
the interior of the rear disc brake rotor as a drum
(hat section of drum-in-hat style brake rotor).
Fig. 7 ANTI-RATTLE DEVICES ON CALIPERS
1 - CONTINENTAL TEVES CALIPER
2 - TRW CALIPER
3 - ANTI-RATTLE CLIP
4 - ANTI-RATTLE CLIP
Fig. 8 Externally and Internally Vented Rotors
(Cross-Sectional View)
1 - EXTERNAL VENTS (TRW)
2 - INTERNAL VENTS (Continetal Teves)
Fig. 9 Rear Disc Brakes
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RSBRAKES - BASE5-11
HYDRAULIC/MECHANICAL (Continued)

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.
BRAKE PADS/SHOES - FRONT
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove both front wheel and tire assemblies.
(3) Begin on one side of the vehicle.
(4) Remove the anti-rattle clip from the outboard
side of the caliper and adapter.
(5) Remove the two caliper guide pin bolts.
(6) Remove caliper from caliper adapter and brake
rotor.
CAUTION: Supporting weight of caliper by the flex-
ible brake fluid hose can damage the hose.
(7) Using wire or cord, hang the caliper from the
front strut assembly (Fig. 12). Support the caliper
firmly to prevent weight of caliper from being sup-
ported by the brake fluid hose.
(8) Remove the outboard brake shoe from the cali-
per adapter.
(9) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip on shoe is free
from the cavity in the caliper piston (Fig. 13).
(10) Repeat the above procedure on other side of
the vehicle.
Fig. 12 Stored Front Disc Brake Caliper
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
RSBRAKES - BASE5-13
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 remove from.
INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)
(1) Begin on one side of the vehicle or the other.
(2) Completely retract the caliper piston back into
its bore in the brake caliper (This is required for cal-
iper installation on the brake rotor with new brake
shoes installed).
(3) If applied, remove the protective paper from
the noise suppression gasket on the rear of both the
inner and outer brake shoe assemblies.
(4) Install the new inboard brake shoe into the cal-
iper piston by firmly pressing its retaining clip into
the piston bore. Be sure the inboard brake shoe is
positioned squarely against the face of the caliper
piston.
(5) Lubricate both adapter abutments where the
shoes slide with a small amount of MopartMultipur-
pose Lubricant, or equivalent.
(6) Slide the new outboard brake shoe into the cal-
iper adapter up against the outside of the brake
rotor.
CAUTION: Use care when installing the caliper
assembly onto the steering knuckle, so the caliper
guide pin bushings do not get damaged by the
steering knuckle bosses.
(7) Carefully position the brake caliper over the
brake rotor and adapter.
(8) 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.
(9) 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.
(10) 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.).
(11) Repeat the above procedure on other side of
the vehicle.
(12) Lower vehicle.
(13) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(14) Check and adjust brake fluid level as neces-
sary.(15) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
NOTE: Perform steps Step 1 through Step 5on each
side of the vehicle.
(1) Place the brake shoes in the adapter anti-rattle
clips.
(2) Completely retract the caliper piston back into
the bore of the caliper.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(3) Install the disc brake caliper over the brake
shoes on the brake caliper adapter.
(4) 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.
14).
(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) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(8) Check and adjust the brake fluid level as nec-
essary.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE PADS/SHOES - REAR
DISC
REMOVAL - REAR DISC BRAKE SHOES
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE).
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 15).
(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. 16).
RSBRAKES - BASE5-15
BRAKE PADS/SHOES - FRONT (Continued)

(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
INSTALLATION - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system (TRW -
disc/drum brake combination and Continental Teves
- disc/disc brake combination). If calipers are inter-
changed, improper performance, noise and
increased stopping distance can occur.
(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)
Fig. 35 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 36 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
RSBRAKES - BASE5-25
DISC BRAKE CALIPERS - FRONT (Continued)

(6) Using a hammer and Installer, Special Tool
C-4689 or C-4842 (depending on piston size), and
Handle, Special Tool C-4171, drive the boot into the
counterbore of the caliper as necessary (Fig. 42).
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
INSTALLATION - REAR DISC BRAKE CALIPER
(1) Completely retract caliper piston back into pis-
ton bore of the caliper.
(2) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
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.
(3) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 38).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to cross-thread the cal-
iper guide pin bolts.(4) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special copper 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.
(7) 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.).
(8) Lower the vehicle.
(9) Remove the brake pedal depressor (holding)
tool.
(10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)
(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.
DISC BRAKE CALIPER
ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove front wheel and tire assembly, disc
brake caliper and brake shoes. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL)
(3) Remove two bolts fastening adapter to steering
knuckle, then remove disc brake caliper adapter.
INSTALLATION - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Place adapter over brake rotor and align
adapter mounting holes to knuckle.
CAUTION: Adapter mounting bolts have a special
DacrometTcoating applied to resist corrosion. If
mounting bolts need to be replaced, use only
MoparTreplacement parts.
Fig. 42 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
RSBRAKES - BASE5-29
DISC BRAKE CALIPERS - REAR (Continued)

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 withABS. 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.
46).
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.
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.
5 - 32 BRAKES - BASERS
FLUID (Continued)

CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(12) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 55). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to
power brake booster (Fig. 55).
(15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Inside vehicle, remove silencer panel under
instrument panel below steering column.
(18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 56).
Fig. 54 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. 55 MASTER CYLINDER MOUNTING
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 56 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
RSBRAKES - BASE5-39
POWER BRAKE BOOSTER (Continued)

(19) 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.
(20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 57).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 58).
CAUTION: Do not attempt to disassemble the power
brake vacuum booster it is serviced ONLY as a
complete assembly.INSTALLATION - POWER BRAKE BOOSTER
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 58).
It may be necessary to push in on booster input rod
as it is guided through the dash panel.
(2) Install the four nuts mounting the booster to
the dash panel (Fig. 57). Tighten the mounting nuts
to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 59).
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.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(6) Install the silencer panel below the steering
column.
(7) Connect vacuum hose to check valve on power
brake booster.
Fig. 57 BOOSTER MOUNTING
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 58 BOOSTER REMOVAL/INSTALLATION
Fig. 59 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
5 - 40 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)