air suspension CHRYSLER VOYAGER 2004 User Guide

SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure 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 cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
(9) Disconnect the park brake cable from the park
brake actuation lever.
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 84) 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) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL)(12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and 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. 85).
(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer to 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION)
(4) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(5) Install the park brake cable on the park brake
actuation lever.
(6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(8) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(9) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(10) Install brake drum.
(11) Install wheel and tire.
(12) Tighten wheel stud nuts to 135 N´m (100 ft.
lbs.).
Fig. 84 Removing Park Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE
2 - CABLE RETAINER
3 - 14 mm BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 85 Brake Support Plate Mounted On Bearing
Attaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
5 - 56 BRAKES - BASERS

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................75
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................75
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............75
DESCRIPTION - TRACTION CONTROL
SYSTEM............................76
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 76
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............77
OPERATION - TRACTION CONTROL
SYSTEM............................77
CAUTION
CAUTIONS..........................78
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................78
SPECIFICATIONS
ABS FASTENER TORQUE...............79
TONE WHEEL RUNOUT................79
WHEEL SPEED SENSOR AIR GAP........79
FRONT WHEEL SPEED SENSOR
REMOVAL.............................79
INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................80INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................81
INSTALLATION.........................81
TONE WHEEL
INSPECTION - TONE WHEEL..............82
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................82
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................83
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................89
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................90
REMOVAL
REMOVAL - LHD......................90
REMOVAL - RHD......................91
DISASSEMBLY - ICU....................93
ASSEMBLY - ICU.......................94
INSTALLATION
INSTALLATION - LHD..................94
INSTALLATION - RHD..................95
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE SYSTEM
This section covers the physical and operational
descriptions and the on-car service procedures for the
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control.
The purpose of the antilock brake system (ABS) is
to prevent wheel lockup under braking conditions on
virtually any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
DESCRIPTION - ANTILOCK BRAKE SYSTEM
(EXPORT)
Four-wheel disc antilock brakes are standard on all
models. The Mark 20e antilock brake system is used
on all models. Depending on whether the vehicle is a
left-hand drive (LHD) or right-hand drive (RHD)
model, the integrated control unit (ICU) is located in
one of two locations. On LHD models, the ICU is
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
RSBRAKES - ABS5-75

CONDITION POSSIBLE CAUSES CORRECTION4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL 1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment. 1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)
CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
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.
² Left Rear Wheel
² Right Front Wheel
² Right Rear Wheel
² Left Front Wheel
NOTE: When bleeding the brake system, some air
may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder
screw (Fig. 1). Therefore, it is essential to have a
fast flow of a large volume of brake fluid when
bleeding the brakes to ensure all the air gets out. The brakes may be manually bled or pressure bled.
Refer to the appropriate following procedure.
MANUAL BLEEDING PROCEDURE
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. (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.
CAUTION: ªJust crackingº the bleeder screw often
restricts fluid flow, allowing only a slow, weak fluid
discharge of fluid. This practice will NOT get all the
air out. Make sure the bleeder is opened at least 1
full turn when bleeding.
(3) Release the brake pedal only afterthe bleeder
screw is closed. (4) Repeat steps 1 through 3, four or five times, at
each bleeder screw in the proper 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) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Continue to bleed system as necessary. (6) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
Fig. 1 Trapped Air In Brake Fluid Line
1 - TRAPPED AIR
RS BRAKES5s-7
BRAKES - BASE (Continued)

Use only brake fluid that was stored in a tightly-
sealed container. DO NOT use 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 Mopar tBrake
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 with
ABS. 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. 44).
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 t o 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 t o 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. (4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 44). (5) Remove the primary and secondary brake
tubes from the top of the junction block. (6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.). (2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
5s - 32 BRAKESRS
FLUID (Continued)

(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.). (4) If the vehicle is equipped with speed control,
perform the following: (a) Install the speed control servo with its
mounting nuts. (b) Connect the wiring harness to the speed con-
trol servo. (c) Install the battery tray (Refer t o 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION). (d) Install the screw securing the coolant filler
neck to the battery tray. (e) Reconnect the vacuum hose connector at the
tank built into the battery tray. (f) Install the battery (Refer t o 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION). (g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery. (7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer t o 5 - BRAKES - STANDARD PROCE-
DURE). (8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 45). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
For information on master cylinder application,
bore and type, view the following table:
BRAKE SYSTEM MASTER CYLINDER
BORE/TYPE
Disc/Drum - ABS 23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Drum - Non-ABS 23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Disc - ABS 25.4 mm (1.0 in.)
Conventional
Compensating Port
Disc/Disc ABS With
Traction Control 25.4 mm (1.0 in.) Dual
Center Port
Fig. 44 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
Fig. 45 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RS BRAKES5s-33
JUNCTION BLOCK (Continued)

brakes will be lower than the front brakes. This will
prevent premature rear wheel lockup and skid.Here is how the height sensing proportioning valve
differs from a standard proportioning valve. As the
height of the rear suspension changes, the height
sensing portion of the proportioning valve changes
the split point of the proportioning valve. When the
height of the rear suspension is low, the proportion-
ing valve interprets this as extra load and the split
point of the proportioning valve is raised to a higher
pressure to allow for more rear braking. When the
height of the rear suspension is high, the proportion-
ing valve interprets this as a light load and the split
point of the proportioning valve is lowered to a lower
pressure and rear braking is reduced. The height sensing proportioning valve regulates
the pressure by sensing the load condition of the
vehicle through the movement of the proportioning
valve actuator lever (Fig. 80). As the position of the
rear axle changes, depending on the load the vehicle
is carrying, the movement is transferred to the pro-
portioning valve. The proportioning valve adjusts the
hydraulic pressure accordingly. The height sensing proportioning valve allows the
brake system to maintain the optimal front to rear
brake balance regardless of the vehicle load condi-
tion. Under a light load condition, hydraulic pressure
to the rear brakes is minimized. As the rear load con-
dition increases, so does the hydraulic pressure to
the rear brakes.
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE (HEIGHT SENSING)
CAUTION: The use of aftermarket load leveling or
load capacity increasing devices on this vehicle is
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.
When a premature rear wheel skid is obtained on a
brake application, it may be an indication that the
hydraulic pressure to the rear brakes is above the
specified output from the proportioning valve. This
condition indicates a possible malfunction of the
height sensing proportioning valve, which will
require testing to verify that it is properly controlling
the hydraulic pressure allowed to the rear brakes.
Premature rear wheel skid may also be caused by
contaminated front or rear brake linings. Prior to testing a proportioning valve for function,
check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory
condition.
It is also necessary to verify that the
brakes shoe assemblies on a vehicle being
tested are either original equipment manufac-
turers (OEM) or original replacement brake
shoe assemblies meeting the OEM lining mate-
rial specification. This vehicles brake system is
not balanced for aftermarket brake shoe assem-
bly lining material. If both front and rear brakes check OK, proceed
with the following test procedure for the height sens-
ing proportioning valve. (1) Road test the vehicle to determine which rear
wheel brake is exhibiting premature wheel skid. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (3) Remove the chassis brake tube going to the
rear brake in question at the proportioning valve.
Remove the chassis brake tube coming from the junc-
tion block at the proportioning valve (Fig. 81). (4) Install the appropriate fittings from Pressure
Test Fittings, Special Tool 6833, into the open ports
of the proportioning valve. (5) Install the previously removed brake lines into
the Pressure Test Fittings. Tighten all tube nuts to
17 N´m (145 in. lbs.). (6) Install a pressure gauge from Gauge Set, Spe-
cial Tool C-4007-A into the open port on each pres-
sure test fitting. Bleed air out of hose from pressure
test fittings to pressure gauges at the pressure
gauges. Then bleed air out of the brake line being
tested at that rear wheel brake bleeder.
NOTE: Actuator rod is a linear spring and is meant
to flex by design. When rod is raised, it will have
some curvature to it.
(7) Remove the screw fastening the proportioning
valve actuator rod bracket to the rear axle. Raise the
actuator lever to the full-upward position and hold it
there. (8) With the aid of a helper, apply pressure to the
brake pedal until a pressure of 6895 kPa (1000 psi) is
obtained on the proportioning valve inlet gauge.
Then, based on the type of brake system the vehicle
is equipped with and the pressure specification
shown on the following table, compare the pressure
reading on the outlet gauge to the specification. If
outlet pressure at the proportioning valve is not
within specification when required inlet pressure is
obtained, replace the proportioning valve. (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/PROPOR-
TIONING VALVE - REMOVAL)
5s - 52 BRAKESRS
PROPORTIONING VALVE (Continued)

LIMITS/SPECIFICATIONS
Braking Rotor Rotor ThicknessMinimum Rotor
Thickness Rotor Thickness
Variation Rotor Runout*
Front - TRW 27.87±28.13 mm
1.097-1.107 in. 25.3 mm
0.996 in. 0.009 mm
0.0004 in. 0.075 mm
0.0030 in.
Front - Continental Teves 27.90±28.10 mm
1.098-1.106 in. 25.3 mm
0.996 in. 0.008 mm
0.0003 in. 0.100 mm
0.0039 in.
Rear 12.4±12.6 mm
0.488 -0.496 in. 11.25 mm
0.443 in. 0.013 mm
0.0005 in. 0.14 mm
0.0055 in.
*
TIR Total Indicator Reading (Measured On Vehicle)
BRAKE ROTOR - EXPORT
NOTE: Use the following information on all 4 wheel
disc brake vehicles that are equipped with BR3
sales code. When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.
LIMITS/SPECIFICATIONS
Brake Rotor Rotor Thickness Minimum Rotor
Thickness Rotor Thickness
Variation Rotor Runout*
Front 27.9-28.1 mm
1.098 -1.106 in. 26.5 mm
1.043 in 0.010 mm
0.0004 in. 0.080 mm
0.0031 in.
Rear 12.4-12.6 mm
0.488-0.496 in. 11.25 mm
0.443 in. 0.013 mm
0.0005 in. 0.14 mm
0.0055 in.
* TIR Total Indicator Reading (Measured On Vehicle)
SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure 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 cylinder. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends (5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer t o 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL). (7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate. (8) Remove the wheel cylinder from the brake sup-
port plate. (9) Disconnect the park brake cable from the park
brake actuation lever. (10) Using a suitable tool such as a 14 mm box
wrench (Fig. 92) 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) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL) (12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and 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. 93).
5s - 58 BRAKESRS
ROTOR (Continued)

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M12 (1) 106 78 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M10 (4) 61 45 Ð
Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 Ð
Radiator Support Crossmember Attaching Bolts 51 38 Ð
FRONT CRADLE
CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER
This vehicle uses a one piece cast aluminum cradle
for the front cradle crossmember. The cradle cross-
member is used as the attaching points for the lower
control arms, stabilizer bar and steering gear. The
cradle also has the power steering hoses and the
chassis brake tubes attached to it.
WARNING: If a threaded hole in the suspension cra-
dle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the front cradle crossmem-
ber that are used for attachment of the lower control
arm rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair is
done by the installation of a Heli-Coiltthread insert
which has been specifically developed for this appli-
cation. Refer to the Mopar Parts Catalog for the spec-
ified Heli-Coiltthread insert to be used for this
application. The procedure for installing the Heli-
Coiltthread insert is detailed in the Service Proce-
dures section in this group of the service manual.
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.The threaded holes in the front cradle crossmem-
ber, if damaged, can repaired by installing a Heli-
Coiltthread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the cradle crossmember to be repaired, elim-
inating the need to replace the cradle crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for
the repair of M8x1.25 and M10x1.5 threads. Be sure
the correct tools are used for the required thread
insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
RSFRAME & BUMPERS13-9
FRAME (Continued)

REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT(Fig. 10).
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
REMOVAL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 11).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 12).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 13).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 15).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 14).
(24) Remove cradle crossmember from vehicle (Fig.
15).
Fig. 10 FRONT CRADLE CROSSMEMBER CAGED
NUT
1 - BRACKET
2 - CAGED NUT
Fig. 11 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)

(6) Start engine and let idle just long enough to
circulate power steering fluid through the analyzer
and hoses. Shut off engine.
(7) Check power steering fluid level and add fluid
as necessary. Start engine again and let idle until the
air is out of the fluid.
(8) Gauge should read below 300 psi (2068 kPa). If
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure should be in the range
of 100-275 psi (689-1896 kPa) depending on fluid
temperature. The flow meter should read above 1.5
GPM.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than four seconds as the pump could be
damaged.
NOTE:
Power steering pump maximum pressure for
2.4L engines is 1,200 ± 1,350 psi (8,274 ± 9,308 kPa).
Power steering pump maximum pressure for all other
engines is 1,400 ± 1,500 psi (9,653 ± 10,342 kPa).
(9) Close analyzer valve fully three times and
record highest pressure indicated each time. All three
readings must be within specifications. If any of the
three power steering pump pressures are above orbelow specifications, replace pump. (Refer to 19 -
STEERING/PUMP - REMOVAL)
CAUTION: Do not force the steering to operate
against the stops for more than 4 seconds at a time
because pump damage can result.
(10) Once the pump has been verified as working
correctly, completely open the valve on the Power
Steering Analyzer. Turn the steering wheel to the
extreme left until the stop in the steering gear is
met. Hold it there for 2±4 seconds, then release it.
Now turn the steering wheel to the right until the
right stop is met. Hold it there for 2±4 seconds, then
release it. Record the stabilized pressure at each
position. Compare the recorded readings to the spec-
ifications. If the output pressures are not within 100
psi (689 kPa) of one another against either stop or
are below specifications, the steering gear is leaking
internally and must be replaced. (Refer to 19 -
STEERING/GEAR - REMOVAL)
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering column
shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
3. Mis-routed power steering hose. 3. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other components
and objects.
RATTLE OR EXCESSIVE
CLUNK**1. Power steering gear loose on front
suspension crossmember.1. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to
the specified torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
RSSTEERING19-3
STEERING (Continued)