torque CHRYSLER VOYAGER 2003 Workshop Manual

This lock-up is not desired, and requires the use of
another mechanism to prevent the lock-up. The
device that prevents undesired high-speed lock-up is
called a9high speed latch9.
Similar to the friction shoes, the two-piece high-
speed latch will separate from each other at high
rotational speeds due to centrifugal effects. (Fig. 35)
shows the high speed latch engaged. The gap9x9
increases with speed, eventually locking into one of
the slots in the BOC shaft. When the high-speed
latch is activated (propeller shaft speed reaches X
amount), the cage is partially fixed, and cannot lock
on the wrong side of the flat as shown (Fig. 34). The
high speed latch is a one way device and does not
prevent high-speed lockup in the reverse direction. At
high speeds, the BOC provides the same function as
low speeds, transferring torque to the viscous coupler
only when front wheel slip overcomes the axle ratio
offset.
At high speed, the rollers are forced outward to the
outer race because of centrifugal force. At high
speeds, the friction shoes can no longer prevent lock-
up. When the teeth on the high-speed latch engage
into the input shaft, it keeps the rollers centered
above the flats because the tabs on the latch are
locked into the cage. (Fig. 36) shows the roller config-
uration with the High-Speed Latch engaged.
On the BOC shaft, the high speed latch teeth lock
up in the grooved areas, shown in (Fig. 37), when the
turning speed reaches the critical value. (Fig. 37)
Fig. 33 BOC High Speed Latch (Not Engaged)
1 - TOOTH (TWO PLACES)
2 - GARTER SPRING
3 - TABS AT BOTH ENDS FIT INTO SLOTS IN CAGE
4 - TWO PART DESIGN
Fig. 34 BOC Operation During High Speed Lock-up Without High Speed Latch
3 - 38 REAR DRIVELINE MODULERS
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)
ProCarManuals.com

also shows the outer race/viscous coupler. Notice the
surface (outer race) the rollers mate against when
transferring torque.
DIFFERENTIAL ASSEMBLY
DESCRIPTION
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
OPERATION
In operation, power flow occurs as follows:
²The pinion gear rotates the ring gear
²The ring gear (bolted to the differential case)
rotates the case
²The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
²The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig.
38).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
39). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
Fig. 35 High Speed Latch Engaged
1 - CAGE FORCE EXERTED BY ROLLERS AT HIGH SPEED
Fig. 36 BOC Operation at High Speed with High
Speed Latch
Fig. 37 BOC Input Shaft
1 - GROOVED AREA (2 LOCATIONS)
2 - ROLLER MATING SURFACE
RSREAR DRIVELINE MODULE3-39
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)
ProCarManuals.com

now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
FLUID - DIFFERENTIAL
ASSEMBLY
STANDARD PROCEDURE - DIFFERENTIAL
ASSEMBLY FLUID CHANGE
The drain plug (Fig. 40) for the differential assem-
bly is located in the bottom of the differential assem-
bly case, toward the rear of the unit.
The fill plug (Fig. 41) for the differential assembly
is located on the rear of the assembly case.The correct fill level is to the bottom of the fill plug
hole. Be sure the vehicle is on a level surface, or is
hoisted in a level manner, in order to obtain the cor-
rect fill level.
(1) Raise the vehicle on a hoist.
(2) Position a drain pan under the differential
drain plug (Fig. 40).
(3) Remove the drain plug and allow the fluid to
drain into the pan.
(4) Install the drain plug and torque to 35 N´m (26
ft. lbs.).
Fig. 38 Differential OperationÐStraight Ahead
Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 39 Differential OperationÐOn Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 40 Differential Drain Plug
1 - DIFFERENTIAL DRAIN PLUG
Fig. 41 Differential Fill Plug
1 - DIFFERENTIAL FILL PLUG
3 - 40 REAR DRIVELINE MODULERS
DIFFERENTIAL ASSEMBLY (Continued)
ProCarManuals.com

(5) Re-position the drain pan under the differential
fill plug.
(6) Remove the differential fill plug (Fig. 41).
(7) Using a suction gun (Fig. 42) or equivalent, fill
the differential assembly with 0.7 L (1.48 pts.) of
MopartGear and Axle Lubricant (80W-90).
(8) Install the fill plug and torque to 35 N´m (26 ft.
lbs.).
FLUID - OVERRUNNING
CLUTCH HOUSING
STANDARD PROCEDURE - OVERRUNNING
CLUTCH HOUSING FLUID CHANGE
(1) Raise vehicle on hoist.
(2) Position a drain pan under overrunning clutch
housing drain plug.
(3) Remove overrunning clutch housing drain plug
and drain fluid (Fig. 43).
(4) Install the drain plug and torque to 30 N´m (22
ft. lbs.).
(5) Re-position the drain pan under the overrun-
ning clutch housing fill plug.
(6) Remove fill plug (Fig. 44).
(7) Using a suction gun (Fig. 45), add 0.58 L (1.22
pts.) of MopartATF+4 (Automatic Transmission Flu-
idÐType 9602).
(8) Install fill plug and torque to 30 N´m (22 ft.
lbs.).
VISCOUS COUPLER
DESCRIPTION
The heart of the all-wheel drive system is the
inter-axle viscous coupling and bi-directional over-
running clutch. Under normal driving the vehicle
retains predominantly front wheel drive characteris-
tics. The all-wheel drive takes effect when the front
wheels start to slip. Under normal level road,
straight line driving, 100% of the torque is allocated
to the front wheels. The viscous coupler allows more
Fig. 42 Filling Differential
1 - DIFFERENTIAL ASSEMBLY
2 - SUCTION GUN
Fig. 43 Overrunning Clutch Case Drain Plug
1 - OVERRUNNING CLUTCH HOUSING DRAIN PLUG
Fig. 44 Overrunning Clutch Housing Fill Plug
1 - OVERRUNNING CLUTCH HOUSING FILL PLUG
2 - FUEL TANK
RSREAR DRIVELINE MODULE3-41
FLUID - DIFFERENTIAL ASSEMBLY (Continued)
ProCarManuals.com

torque to the rear wheels in accordance with the
amount of slippage at the front wheels. The variable
torque distribution is automatic with no driver
inputs required.
OPERATION
The viscous coupler (Fig. 46) is a housing nearly
filled with a high viscosity silicone liquid and thin
metal plates alternately splined to an inner and
outer drum. The viscous coupler provides torque in
the following modes:²Shear mode (normal operation)
²Hump mode (locked mode)
The inner plates are slotted around the radius and
the outer plates have holes in them. In the shear
mode (normal operation), the plates are evenly
spaced and the torque is created by the shearing of
the plates through the fluid and 90-100% of the
torque is applied to the rear axle. During the shear
mode, a fluid flow pattern is created from this design
(holes and slots). This fluid flow causes high pressure
on each side of each pair of plates and low pressure
between each pair of plates.
When a high speed difference (shear) occurs
because of loss of traction (one axle spinning faster
than the other), the silicone fluid expands as it heats
from this shearing. When the silicone expands to fill
the viscous coupler completely, this pressure differ-
ence is high enough to squeeze each pair of plates
together. The resulting hump torque is up to 8 times
higher than the shear torque. When the viscous cou-
pler is in the hump mode, it does not lock the axles
(undifferentiated 4-Wheel Drive). It controls the
amount of slippage while delivering maximum power
to the axle having greatest traction. Once the speed
difference equalizes the fluid and plates cool down
and the viscous coupler goes back to the shear mode.
Fig. 45 Filling Overrunning Clutch Case
1 - OVERRUNNING CLUTCH HOUSING FILL HOLE
2 - SUCTION GUN
3 - 42 REAR DRIVELINE MODULERS
VISCOUS COUPLER (Continued)
ProCarManuals.com

TORQUE ARM
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear driveline module assembly. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIV-
ELINE MODULE - REMOVAL)
(3) Remove six torque arm-to-differential assembly
bolts (Fig. 47). Remove torque arm.
INSTALLATION
(1) Install six torque arm-to-differential assembly
bolts (Fig. 47) and torque to 60 N´m (44 ft. lbs.).
(2) Install rear driveline module assembly. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIV-
ELINE MODULE - INSTALLATION)
(3) Lower vehicle.
INPUT FLANGE SEAL
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT -
REMOVAL)
(3) Using tool 6958, remove input flange nut and
washer (Fig. 48).
(4) Remove input flange (Fig. 49).(5) Using suitable screwdriver, remove input
flange seal from overrunning clutch housing (Fig.
50).
Fig. 47 Torque Arm Fasteners
1 - TORQUE ARM ASSEMBLY
2 - BOLT (SIX)
Fig. 48 Input Flange Nut
1 - INPUT FLANGE
2 - TOOL 6958
Fig. 49 Input Flange
1 - INPUT FLANGE/SHIELD
3 - 44 REAR DRIVELINE MODULERS
ProCarManuals.com

INSTALLATION
(1) Using tool 8802, install input flange seal to
overrunning clutch case (Fig. 51).
(2) Install input flange (Fig. 52).
(3) Install flange nut and washer. Using tool 6958,
torque flange nut to 135 N´m (100 ft. lbs.) (Fig. 53).
(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT -
INSTALLATION)
(5) Lower vehicle.
OUTPUT FLANGE SEAL
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear halfshaft inner joint at differen-
tial output flange (Fig. 54).
(3) Using two screwdrivers and wood blocks to pro-
tect differential housing casting, pry output flange
out of differential (Fig. 55).
(4) Use suitable screwdriver to remove output
flange seal (Fig. 56).
Fig. 50 Input Flange Seal Removal
1 - INPUT FLANGE SEAL
2 - SCREWDRIVER
Fig. 51 Input Flange Seal Installation
1 - TOOL 8802
2 - HAMMER
Fig. 52 Input Flange
1 - INPUT FLANGE/SHIELD
Fig. 53 Input Flange Nut
1 - INPUT FLANGE
2 - TOOL 6958
RSREAR DRIVELINE MODULE3-45
INPUT FLANGE SEAL (Continued)
ProCarManuals.com

(2) Install ouput flange to differential assembly.
Verify that it is seated all the way into position by
attempting to pull out by hand.
(3) Install rear halfshaft inner joint to output
flange.
(4) Install and torque bolts to 61 N´m (45 ft. lbs.)
(Fig. 58).
(5) Check differential assembly fluid level and
adjust as required. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/REAR DRIVELINE MODULE/FLUID -
STANDARD PROCEDURE)
Fig. 58 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
RSREAR DRIVELINE MODULE3-47
OUTPUT FLANGE SEAL (Continued)
ProCarManuals.com

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 75
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES..............3
WARNING.............................4
CAUTION..............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................4
STANDARD PROCEDURE - BASE BRAKE
BLEEDING............................7
SPECIFICATIONS
BRAKE FASTENER TORQUE.............9
SPECIAL TOOLS
BASE BRAKE SYSTEM.................10
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................11
INSTALLATION.........................11
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 11
DESCRIPTION - DISC BRAKES (REAR)....12
DESCRIPTION - DISC BRAKES (EXPORT) . . 13
DESCRIPTION - DRUM BRAKES (REAR) . . . 13
OPERATION
OPERATION - DISC BRAKES (FRONT).....13
OPERATION - DISC BRAKES (REAR)......13
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................13
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES . 14
OPERATION - BRAKE TUBES AND HOSES . . . 14
INSPECTION - BRAKE TUBES AND HOSES . . . 14BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)..................14
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES).................15
CLEANING - DISC BRAKE SHOES..........16
INSPECTION - DISC BRAKE SHOES........16
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DISC BRAKES)............16
INSTALLATION - FRONT DISC BRAKE
SHOES (DISC/DRUM BRAKES)...........17
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....17
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION - REAR DISC BRAKE SHOES . . 19
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....19
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................22
INSTALLATION - REAR DRUM BRAKE SHOES . 22
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................23
DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)..................24
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES).................24
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........24
DISASSEMBLY - CALIPER PISTON AND
SEAL...............................24
RSBRAKES5-1
ProCarManuals.com

CLEANING - CALIPER...................25
INSPECTION - CALIPER..................25
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES).........25
ASSEMBLY - CALIPER PISTON AND SEAL . . 26
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DISC BRAKES)...........27
INSTALLATION - FRONT DISC BRAKE
CALIPER (DISC/DRUM BRAKES)..........27
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER....27
DISASSEMBLY - CALIPER PISTON AND SEAL . 28
CLEANING - CALIPER...................29
INSPECTION - CALIPER..................29
ASSEMBLY - CALIPER PISTON AND SEAL . . . 29
INSTALLATION - REAR DISC BRAKE CALIPER . 30
DISC BRAKE CALIPER ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER...........................31
INSTALLATION - FRONT DISC BRAKE
CALIPER ADAPTER....................31
DISC BRAKE CALIPER GUIDE PINS
REMOVAL - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES).............31
INSTALLATION - DISC BRAKE CALIPER
GUIDE PINS (DISC/DRUM BRAKES).......31
DRUM
REMOVAL.............................32
INSTALLATION.........................32
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................32
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING.....................32
SPECIFICATIONS
BRAKE FLUID........................33
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK . 33
OPERATION - NON-ABS JUNCTION BLOCK . . 33
REMOVAL - NON-ABS JUNCTION BLOCK....33
INSTALLATION - NON-ABS JUNCTION BLOCK . 33
MASTER CYLINDER
DESCRIPTION
DESCRIPTION........................34
DESCRIPTION - RHD..................35
OPERATION...........................35
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................35
REMOVAL
REMOVAL - LHD......................36
REMOVAL - RHD......................37
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................37
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR).........................38INSTALLATION
INSTALLATION - LHD..................38
INSTALLATION - RHD..................39
PEDAL TORQUE SHAFT - RHD
REMOVAL.............................39
INSTALLATION.........................39
POWER BRAKE BOOSTER
DESCRIPTION.........................40
OPERATION...........................41
DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER...........................41
REMOVAL
REMOVAL - LHD......................42
REMOVAL - RHD......................43
INSTALLATION
INSTALLATION - LHD..................46
INSTALLATION - RHD..................47
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)....................48
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................48
DIAGNOSIS AND TESTING -
PROPORTIONING VALVE (HEIGHT
SENSING)...........................49
REMOVAL - PROPORTIONING VALVE
(HEIGHT SENSING)....................50
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)....................51
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR . . 51
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING..........................53
REMOVAL - FRONT BRAKE ROTOR........54
INSTALLATION - FRONT BRAKE ROTOR.....54
SPECIFICATIONS
BRAKE ROTOR.......................55
BRAKE ROTOR - EXPORT..............55
SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................56
INSTALLATION.........................56
WHEEL CYLINDERS
REMOVAL.............................57
INSPECTION..........................57
INSTALLATION.........................57
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................57
DESCRIPTION - EXPORT...............58
OPERATION...........................58
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................58
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................59
5 - 2 BRAKES - BASERS
ProCarManuals.com