height CHRYSLER VOYAGER 2004 User Guide

(12) If the vehicle is equipped with the 2.5L diesel
engine, install the coolant recovery pressure con-
tainer and bracket. (Refer to 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
INSTALLATION)
(13) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.).
(14) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.).
(15) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray.
(16) Install the battery, clamp and mounting nut.
(17) Install the positive battery cable on the bat-
tery.
(18) Install the negative battery cable on the bat-
tery.
(19) Install the battery thermal guard shield.
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.
(20) 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)(21) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(22) Road test vehicle to ensure proper operation
of the brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. It is mounted to the body of
the vehicle above the rear axle (Fig. 72). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
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.
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)
Vehicles not equipped with ABS use a height sens-
ing proportioning valve.
The height sensing proportioning valve operates
similarly to a standard proportioning valve in the fol-
lowing way. As hydraulic pressure is applied to the
valve, full input hydraulic pressure is supplied to the
rear brakes up to a certain pressure point, called the
split point. Beyond the split point, the proportioning
valve reduces the amount of hydraulic pressure to
the rear brakes according to a given ratio. Thus, on
light brake applications, approximately equal
hydraulic pressure will be transmitted to both the
front and rear brakes. Upon heavier brake applica-
tions, the hydraulic pressure transmitted to the rear
brakes will be lower than the front brakes. This will
prevent premature rear wheel lockup and skid.
Fig. 71 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
5 - 48 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)

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. 72). 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 helpersprings 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. 73).
(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.
Fig. 72 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
RSBRAKES - BASE5-49
PROPORTIONING VALVE (Continued)

(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)
CAUTION: Do not attempt to adjust the height sens-
ing proportioning valve. If found to be defective,
replace the valve.(9) Remove the pressure test fittings and pressure
gauges from the proportioning valve.
(10) Install the chassis brake lines in the correct
ports of the proportioning valve. Tighten all tube
nuts to 17 N´m (145 in. lbs.).
(11) If necessary, repeat the above steps on the
remaining side of the proportioning valve which con-
trol the other rear wheel brake.
(12) Attach the actuator lever and bracket to the
rear axle.
(13) Bleed rear brakes. (Refer to 5 - BRAKES -
STANDARD PROCEDURE)
(14) Road test vehicle.
PROPORTIONING VALVE SPECIFICATIONS
WHEEL
BASEDRIVE
TRAINSALES CODE BRAKE SYSTEMSPLIT
POINTSLOPEINLET
PRESSURE
PSIOUTLET
PRESSURE
PSI
SWB FWD BRB-BGF159DISC/DRUM
W/O ANTILOCKVAR. .59 1000 PSI 675-875 PSI
REMOVAL - PROPORTIONING VALVE (HEIGHT
SENSING)
(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 proportioning valve.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the four brake tubes from the inlet and
outlet ports of the proportioning valve (Fig. 73).
(4) Remove the two bolts attaching the proportion-
ing valve and bracket to the vehicle (Fig. 73).
(5) Slide the bracket out from under rear track bar
bracket. Lower the valve down enough to pull its
actuator rod out of the axle bracket and remove the
proportioning valve from the vehicle.
Fig. 73 PROPORTIONING VALVE MOUNTING
1 - LEFT REAR OUTLET TUBE
2 - RIGHT REAR OUTLET TUBE
3 - RIGHT REAR INLET TUBE
4 - MOUNTING BOLTS
5 - LEFT REAR INLET TUBE
5 - 50 BRAKES - BASERS
PROPORTIONING VALVE (Continued)

INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)
(1) Install the end of the actuator rod through the
axle bracket grommet and slide the proportioning
valve bracket under the rear track bar body bracket
(Fig. 73).
(2) Install the proportioning valve attaching bolts
(Fig. 73). Tighten the attaching bolts to a torque of
54 N´m (40 ft. lbs.).
(3) Install the four chassis brake lines into the
inlet and outlet ports of the proportioning valve (Fig.
73). Tighten all tube nuts to a torque of 17 N´m (145
in. lbs.).
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it.
(4) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - BASE - STANDARD
PROCEDURE).
(5) Lower the vehicle to the ground.
(6) Road test the vehicle to verify proper operation
of the brake system.
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock-back. This increases
guide pin sleeve wear due to the tendency of the cal-
iper to follow the rotor wobble.
When diagnosing a brake noise or pulsation, the
machined disc braking surface should be checked and
inspected.
BRAKING SURFACE INSPECTION
Light braking surface scoring and wear is accept-
able. If heavy scoring or warping is evident, the rotor
must be refaced or replaced. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTORS - STAN-
DARD PROCEDURE).
Excessive wear and scoring of the rotor can cause
improper lining contact on the rotor's braking sur-
face. If the ridges on the rotor are not removed before
new brake shoes are installed, improper wear of the
shoes will result.
If a vehicle has not been driven for a period of
time, the rotor's braking surface will rust in the
areas not covered by the brake shoes at that time.
Once the vehicle is driven, noise and chatter fromthe disc brakes can result when the brakes are
applied.
Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced. If cracks or burned spots are evi-
dent, the rotor must be replaced.
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if it is worn
below minimum thickness or if machining the rotor
will cause its thickness to fall below specifications.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Minimum thickness specifications are cast on the
rotor's unmachined surface (Fig. 74). Limits can also
be found in this section's specification table. (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
SPECIFICATIONS)
ROTOR THICKNESS VARIATION
Thickness variation in a rotor's braking surface
can result in pedal pulsation, chatter and surge. This
can also be caused by excessive runout in the rotor or
the hub.
Rotor thickness variation measurements should be
made in conjunction with measuring runout. Mea-
sure thickness of the brake rotor at 12 equal points
around the rotor braking surface with a micrometer
at a radius approximately 25 mm (1 inch) from edge
of rotor (Fig. 75). If thickness measurements vary
beyond the specification listed in the specifaction
table (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTOR - SPECIFICATIONS), the rotor should
be refaced or replaced. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE).
Fig. 74 Minimum Brake Rotor Thickness Markings
(Typical)
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
RSBRAKES - BASE5-51
PROPORTIONING VALVE (Continued)

DISC BRAKE CALIPER ADAPTERREMOVAL - FRONT DISC BRAKE CALIPERADAPTER ...........................30
INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER ....................30
DISC BRAKE CALIPER GUIDE PINS REMOVAL - DISC BRAKE CALIPER GUIDEPINS (TRW BRAKES) ..................30
INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) .............30
DRUM REMOVAL .............................31
INSTALLATION .........................31
FLUID DIAGNOSIS AND TESTING - BRAKE FLUIDCONTAMINATION .....................31
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING .....................31
SPECIFICATIONS BRAKE FLUID ........................32
JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK . 32
OPERATION - NON-ABS JUNCTION BLOCK . . 32
REMOVAL - NON-ABS JUNCTION BLOCK ....32
INSTALLATION - NON-ABS JUNCTION BLOCK . 32
MASTER CYLINDER DESCRIPTION DESCRIPTION ........................33
DESCRIPTION - RHD ..................34
OPERATION ...........................34
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING ..................34
REMOVAL REMOVAL - LHD ......................35
REMOVAL - RHD ......................36
DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................36
ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................37
INSTALLATION INSTALLATION - LHD ..................37
INSTALLATION - RHD ..................38
PEDALS - ADJUSTABLE REMOVAL .............................38
INSTALLATION .........................40
PEDAL TORQUE SHAFT - RHD REMOVAL .............................42
INSTALLATION .........................43
POWER BRAKE BOOSTER DESCRIPTION .........................43
OPERATION ...........................44
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER ...........................44
REMOVAL REMOVAL - LHD ......................45
REMOVAL - RHD ......................47 INSTALLATION
INSTALLATION - LHD ..................49
INSTALLATION - RHD ..................50
PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE(HEIGHT SENSING) ....................51
OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................51
DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT
SENSING) ...........................52
REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
ROTOR DIAGNOSIS AND TESTING - BRAKE ROTOR . . 54
STANDARD PROCEDURE - BRAKE ROTORMACHINING ..........................56
REMOVAL - FRONT BRAKE ROTOR ........57
INSTALLATION - FRONT BRAKE ROTOR .....57
SPECIFICATIONS BRAKE ROTOR .......................57
BRAKE ROTOR - EXPORT ..............58
SUPPORT PLATE - DRUM BRAKE REMOVAL .............................58
INSTALLATION .........................58
WHEEL CYLINDERS REMOVAL .............................59
INSPECTION ..........................59
INSTALLATION .........................60
PARKING BRAKE DESCRIPTION DESCRIPTION ........................60
DESCRIPTION - EXPORT ...............60
OPERATION ...........................60
STANDARD PROCEDURE STANDARD PROCEDURE - PARKINGBRAKE AUTOMATIC ADJUSTER TENSION
RELEASE ...........................61
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION
RESET .............................61
CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE(FRONT) ............................62
REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) ......................62
REMOVAL - PARKING BRAKE CABLE (RIGHT REAR) ........................63
REMOVAL - PARKING BRAKE CABLE (LEFT REAR )..............................64
INSTALLATION INSTALLATION - PARKING BRAKE CABLE(FRONT) ............................65
5s - 2 BRAKESRS

(11) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 71). (12) If the vehicle is equipped with the 2.5L diesel
engine, install the coolant recovery pressure con-
tainer and bracket. (Refer t o 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
INSTALLATION) (13) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.). (14) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.). (15) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray. (16) Install the battery, clamp and mounting nut.
(17) Install the positive battery cable on the bat-
tery. (18) Install the negative battery cable on the bat-
tery. (19) Install the battery thermal guard shield.
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. (20) Remove and replace the brake lamp switch
with a NEW switch. (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION) (21) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE) (22) Road test vehicle to ensure proper operation
of the brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. It is mounted to the body of the vehicle above the rear axle (Fig. 80). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
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.
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. The height sensing proportioning valve operates
similarly to a standard proportioning valve in the fol-
lowing way. As hydraulic pressure is applied to the
valve, full input hydraulic pressure is supplied to the
rear brakes up to a certain pressure point, called the
split point. Beyond the split point, the proportioning
valve reduces the amount of hydraulic pressure to
the rear brakes according to a given ratio. Thus, on
light brake applications, approximately equal
hydraulic pressure will be transmitted to both the
front and rear brakes. Upon heavier brake applica-
tions, the hydraulic pressure transmitted to the rear
Fig. 80 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
RS BRAKES5s-51
POWER BRAKE BOOSTER (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)

CAUTION: Do not attempt to adjust the height sens-
ing proportioning valve. If found to be defective,
replace the valve.(9) Remove the pressure test fittings and pressure
gauges from the proportioning valve. (10) Install the chassis brake lines in the correct
ports of the proportioning valve. Tighten all tube
nuts to 17 N´m (145 in. lbs.). (11) If necessary, repeat the above steps on the
remaining side of the proportioning valve which con-
trol the other rear wheel brake. (12) Attach the actuator lever and bracket to the
rear axle. (13) Bleed rear brakes. (Refer t o 5 - BRAKES -
STANDARD PROCEDURE) (14) Road test vehicle.
PROPORTIONING VALVE SPECIFICATIONS
WHEELBASE DRIVE
TRAIN SALES
CODE BRAKE
SYSTEM SPLIT
POINT SLOPE INLET
PRESSURE PSI OUTLET
PRESSURE PSI
SWB FWD BRB-BGF 15
9DISC/
DRUM W/O ANTILOCK VAR. 0.59 1000 PSI 675-875 PSI
REMOVAL - PROPORTIONING VALVE (HEIGHT
SENSING)
(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 proportioning valve. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the four brake tubes from the inlet and
outlet ports of the proportioning valve (Fig. 81). (4) Remove the two bolts attaching the proportion-
ing valve and bracket to the vehicle (Fig. 81). (5) Slide the bracket out from under rear track bar
bracket. Lower the valve down enough to pull its
actuator rod out of the axle bracket and remove the
proportioning valve from the vehicle.
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)
(1) Install the end of the actuator rod through the
axle bracket grommet and slide the proportioning
valve bracket under the rear track bar body bracket
(Fig. 81). (2) Install the proportioning valve attaching bolts
(Fig. 81). Tighten the attaching bolts to a torque of
54 N´m (40 ft. lbs.). (3) Install the four chassis brake lines into the
inlet and outlet ports of the proportioning valve (Fig.
81). Tighten all tube nuts to a torque of 17 N´m (145
in. lbs.).
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it.
(4) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer t o 5 - BRAKES - BASE - STANDARD
PROCEDURE). (5) Lower the vehicle to the ground.
Fig. 81 PROPORTIONING VALVE MOUNTING
1 - LEFT REAR OUTLET TUBE
2 - RIGHT REAR OUTLET TUBE
3 - RIGHT REAR INLET TUBE
4 - MOUNTING BOLTS
5 - LEFT REAR INLET TUBE
RS BRAKES5s-53
PROPORTIONING VALVE (Continued)

RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION..........................2
OPERATION............................2
WARNING.............................2
DIAGNOSIS AND TESTING - AIRBAG
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS.............................3
STANDARD PROCEDURE - SERVICE
AFTER AN AIRBAG DEPLOYMENT.........3
CHILD RESTRAINT ANCHOR
DESCRIPTION..........................4
OPERATION............................4
CLOCK SPRING
DESCRIPTION..........................4
OPERATION............................4
STANDARD PROCEDURE - CLOCK SPRING
CENTERING..........................5
REMOVAL.............................5
INSTALLATION..........................5
DRIVER AIRBAG
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................7
DRIVER AIRBAG TRIM COVER
REMOVAL.............................7
INSTALLATION..........................7
OCCUPANT RESTRAINT CONTROLLER
DESCRIPTION..........................8
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................8
PASSENGER AIRBAG
DESCRIPTION..........................8
OPERATION............................9
REMOVAL.............................9
INSTALLATION.........................10
SEAT AIRBAG
DESCRIPTION.........................11
OPERATION...........................11
SEAT BELT BUCKLE - FRONT INBOARD
REMOVAL.............................12
INSTALLATION.........................12SEAT BELT BUCKLE - FIRST ROW INBOARD -
QUAD BUCKET
REMOVAL.............................12
INSTALLATION.........................12
SEAT BELT BUCKLE - FIRST ROW - BENCH
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT BUCKLE - SECOND ROW
INBOARD - 50/50 BENCH
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT HEIGHT ADJUSTER-BOR
C-PILLAR
REMOVAL.............................13
INSTALLATION.........................13
SEAT BELT HEIGHT ADJUSTER KNOB
REMOVAL.............................14
INSTALLATION.........................14
SEAT BELT & RETRACTOR - OUTBOARD -
FRONT
REMOVAL.............................14
INSTALLATION.........................14
SEAT BELT & RETRACTOR - FIRST ROW -
OUTBOARD
REMOVAL.............................14
INSTALLATION.........................14
SEAT BELT BUCKLE - SECOND ROW - THREE
PASSENGER BENCH
REMOVAL.............................15
INSTALLATION.........................15
SEAT BELT & RETRACTOR - SECOND ROW -
RIGHT OUTBOARD
REMOVAL.............................15
INSTALLATION.........................15
SEAT BELT & RETRACTOR - SECOND ROW -
RIGHT OUTBOARD WITH REAR HVAC - LWB
REMOVAL.............................16
INSTALLATION.........................16
SEAT BELT & RETRACTOR - SECOND ROW -
LEFT OUTBOARD
REMOVAL.............................17
INSTALLATION.........................17
SEAT BELT TENSIONER
DESCRIPTION.........................17
OPERATION...........................17
RSRESTRAINTS8O-1

SEAT BELT BUCKLE - FIRST
ROW - BENCH
REMOVAL
(1) Remove seat from vehicle.
(2) Remove bolt attaching inboard seat belt buckle
to seat frame (Fig. 7).
(3) Remove belt from seat.
INSTALLATION
(1) Place seat belt into position to the seat.
(2) Install bolt attaching inboard seat belt buckle
to seat frame. Tighten all seat belt anchor bolts to 39
N´m (29 ft. lbs.) torque.
(3) Install seat into position.
SEAT BELT BUCKLE - SECOND
ROW INBOARD - 50/50 BENCH
REMOVAL
(1) Open rear liftgate.
(2) Pull handle #1 and fold seat back forward.
(3) Pull handle #2, and lift seat bottom up.
(4) Pull #3 strap and remove seat from latching
area.
(5) While looking at the bottom of the seat, locate
retaining bolt on the left side of the seat riser.
Remove retaining bolt from seat riser (Fig. 8).
(6) Pull belt through seat cushion.
INSTALLATION
(1) Push belt through seat cushion.(2) While looking at the bottom of the seat, locate
retaining bolt hole on the left side of the seat riser.
Install retaining bolt into seat riser (Fig. 8). Torque
anchor bolt to 39 N´m (29 ft. lbs.).
(3) Place seat into track and on front anchors.
(4) Pull #3 strap and install seat onto latching
area.
(5) Pull seat assembly down firmly and snap into
track.
(6) Pull handle #1 and fold seat back rearward.
(7) Close rear liftgate.
SEAT BELT HEIGHT
ADJUSTER-BORC-PILLAR
REMOVAL
(1) Remove turning loop retaining bolt.
(2) Remove B or C-pillar trim cover.
(3) Remove two screws attaching shoulder belt
height adjuster to pillar.
(4) Remove height adjuster from vehicle.
INSTALLATION
(1) Place height adjuster into position.
(2) Install screws attaching shoulder belt height
adjuster to pillar.
(3) Install B or C-pillar trim cover.
Fig. 7 SEAT BELT BUCKLE - FIRST ROW - BENCH
1 - ANCHOR BOLT
2 - TWO (2) PASS REAR SEAT BELT BUCKLE
3 - RISER
4 - REAR FRAME
Fig. 8 SEAT BELT BUCKLE - SECOND ROW
INBOARD - 50/50 BENCH
1 - SEAT BELT BUCKLE
2 - BUCKLE RETAINING BOLT
3 - 50/50 SPLIT BENCH RISER
4 - BOTTOM OF SEAT CUSHION
RSRESTRAINTS8O-13