brake pads CHRYSLER VOYAGER 2004 Owner's Manual

INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)
(1) Pass front parking brake cable assembly
through hole in floor pan from the inside of the vehi-
cle.
(2) Pass cable strand button through the hole in
the lever (pedal) assembly bracket.
(3) Install cable retainer onto the park brake cable
and then install cable retainer into pedal assembly
bracket.
(4) Install the end of the park brake cable into the
retainer previously installed into the park brake
pedal bracket.
(5) Install cable strand button into the clevis on
the park brake pedal mechanism.
(6) Install the front park brake cable floor pan seal
into hole in floor pan. Seal is to be installed so the
flange on the seal is flush with the floor pan (Fig.
91). Fold carpeting back down on floor.
(7) Raise vehicle.
(8) Insert brake cable and housing into body out-
rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 90).
(9) Manually reset the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 89).
(11) Lower vehicle and apply the park brake pedal
1 time. This will seat the parking brake cables.
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets.
(2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 92) (Fig. 93).
(3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION).
(4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 93).
(5) Install the intermediate park brake cable on
the cable equalizer (Fig. 92).
(6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables.
(7) Install and position the foam collar on the
parking brake cable to prevent it from rattling
against the vehicle's floor.
(8) Lower the vehicle and apply the park brake
pedal 1 time, this will seat the park brake cables.
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park-
ing brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect the right rear parking brake cable to
the connector on the intermediate parking brake
cable (Fig. 95).
(6) Install the brake drum, then the wheel and tire
assembly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Lower the vehicle.
(9) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
Fig. 101 Removing Parking Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
RSBRAKES - BASE5-63
CABLES - PARKING BRAKE (Continued)

INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park
brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 99).
(6) Install brake drum, and wheel and tire assem-
bly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer to 5 - BRAKES/PARKING
BRAKE/SHOES - ADJUSTMENTS).
When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes.
When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
CABLES - PARKING BRAKE
(EXPORT)
REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE).
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel.
(6) Remove the steering column cover from the
lower instrument panel.
(7) Remove the reinforcement from the lower
instrument panel.
(8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 102).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable.
Fig. 102 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5 - 64 BRAKES - BASERS
CABLES - PARKING BRAKE (Continued)

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE DESCRIPTION DESCRIPTION - BASE BRAKES ...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES ..............3
WARNING .............................3
CAUTION ..............................4
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM .............................4
STANDARD PROCEDURE - BASE BRAKE BLEEDING ............................7
SPECIFICATIONS BRAKE FASTENER TORQUE .............8
SPECIAL TOOLS BASE BRAKE SYSTEM ..................9
BRAKE FLUID LEVEL SWITCH DESCRIPTION ..........................9
OPERATION ............................9
REMOVAL .............................10
INSTALLATION .........................10
ADJUSTABLE PEDALS SWITCH REMOVAL .............................10
INSTALLATION .........................10
HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION - DISC BRAKES (FRONT) . . . 10
DESCRIPTION - DISC BRAKES (REAR) ....12
DESCRIPTION - DISC BRAKES (EXPORT) . . 12
DESCRIPTION - DRUM BRAKES (REAR) . . . 12
OPERATION OPERATION - DISC BRAKES (FRONT) .....12
OPERATION - DISC BRAKES (REAR) ......13
DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER ................13
BRAKE LINES DESCRIPTION - BRAKE TUBES AND HOSES . 13
OPERATION - BRAKE TUBES AND HOSES . . . 13
INSPECTION - BRAKE TUBES AND HOSES . . . 13
BRAKE PADS/SHOES - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE SHOES(CONTINENTAL TEVES BRAKES) .........14
REMOVAL - FRONT DISC BRAKE SHOES (TRW BRAKES) .......................14
CLEANING - DISC BRAKE SHOES ..........15
INSPECTION - DISC BRAKE SHOES ........15
INSTALLATION INSTALLATION - FRONT DISC BRAKESHOES (CONTINENTAL TEVES BRAKES) . . . 15 INSTALLATION - FRONT DISC BRAKE
SHOES (TRW BRAKES) ................16
BRAKE PADS/SHOES - REAR DISC REMOVAL - REAR DISC BRAKE SHOES .....16
CLEANING - DISC BRAKE SHOES ..........17
INSPECTION - DISC BRAKE SHOES ........17
INSTALLATION - REAR DISC BRAKE SHOES . . 18
BRAKE PADS/SHOES - REAR DRUM REMOVAL - REAR DRUM BRAKE SHOES ....18
INSPECTION - REAR DRUM BRAKE SHOE LINING ..............................21
INSTALLATION - REAR DRUM BRAKE SHOES . 21
ADJUSTMENTS ADJUSTMENT - REAR DRUM BRAKESHOES .............................22
DISC BRAKE CALIPER - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER(CONTINENTAL TEVES BRAKES) .........23
REMOVAL - FRONT DISC BRAKE CALIPER (TRW BRAKES) .......................23
DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PINBUSHINGS (CONTINENTAL TEVES
BRAKES) ............................23
DISASSEMBLY - CALIPER PISTON AND SEAL ...............................23
CLEANING - CALIPER ...................24
INSPECTION - CALIPER ..................24
ASSEMBLY ASSEMBLY - CALIPER GUIDE PINBUSHINGS (CONTINENTAL TEVES
BRAKES) ............................24
ASSEMBLY - CALIPER PISTON AND SEAL . . 25
INSTALLATION INSTALLATION - FRONT DISC BRAKECALIPER (CONTINENTAL TEVES
BRAKES) ............................26
INSTALLATION - FRONT DISC BRAKE CALIPER (TRW BRAKES) ...............26
DISC BRAKE CALIPER - REAR REMOVAL - REAR DISC BRAKE CALIPER ....26
DISASSEMBLY - CALIPER PISTON AND SEAL . 27
CLEANING - CALIPER ...................28
INSPECTION - CALIPER ..................28
ASSEMBLY - CALIPER PISTON AND SEAL . . . 28
INSTALLATION - REAR DISC BRAKE CALIPER ............................29
RS BRAKES5s-1

line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 3).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch. (3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir. (2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 3).
ADJUSTABLE PEDALS
SWITCH
REMOVAL
(1) Remove steering column lower shroud. (Refer
to 19 - STEERING/COLUMN/LOWER SHROUD -
REMOVAL) (2) Depress retaining tabs on top and bottom of
switch and remove switch from lower shroud.
INSTALLATION
(1) Install the switch into the lower shroud, snap-
ping it into place. (2) Connect wiring harness connector to switch,
then install lower shroud on steering column. (Refer
to 19 - STEERING/COLUMN/LOWER SHROUD -
INSTALLATION) (3) Ensure proper operation of adjustable pedals.
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
Each front disc brake consists of the following com-
ponents: ² Brake Rotor
² Brake Caliper
² Brake Caliper Adapter
² Shoes (Pads)
There are two non-interchangeable front disc brake
systems. One is manufactured by TRW and the other
by Continental Teves.
CAUTION: Components used on the TRW brakes
are not interchangeable with the Continental Teves
brakes. The two different systems must not be
mixed. Improper performance, noise and increased
stopping distance can occur.
The TRW front brake caliper is a one piece casting
containing a single 64 mm diameter piston bore (Fig.
4) with a phenolic piston. The caliper mounts to a
caliper adapter using two guide pin bolts that thread
into guide pins slid into the caliper adapter (Fig. 5).
The pins are lubricated and have boots that seal
them in place in the adapter. The Continental Teves front brake caliper is a one
piece casting containing a single piston 66 mm diam-
eter bore (Fig. 4) with a phenolic piston. The caliper
mounts to a caliper adapter using two guide pin bolts
that thread into the caliper adapter and slide on
bushings mounted in the caliper.
CAUTION: TRW and Continental Teves calipers are
not interchangeable. Each caliper is specifically
designed for the unique brake system. If calipers
are interchanged, improper performance, noise and
increased stopping distance can occur.
Fig. 3 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
5s - 10 BRAKESRS
BRAKE FLUID LEVEL SWITCH (Continued)

DESCRIPTION - DISC BRAKES (REAR)
There are several distinctive features to the rear
disc brakes on this vehicle (Fig. 8). 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 a
drum-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). The outboard rear disc brake shoes (pads) are side-
oriented. The shoes are marked indicating which side
they belong on.
DESCRIPTION - DISC BRAKES (EXPORT)
All vehicles are equipped with Four-Wheel-Disc
brakes. Both 15º (BRE) and 16º (BR3) disc/disc brake
systems are available. The disc brakes are manufac-
tured by Continental Teves. The BR3 system is stan-
dard equipment on all-wheel drive and all right-hand
drive models. It is optional on other models. The BR3 system features larger, externally vented
front brake rotors. Although there are different disc/disc systems, they
are serviced using the same service procedures. Some
specifications differ.
DESCRIPTION - DRUM BRAKES (REAR)
This vehicle's rear wheel drum brakes are a two-
shoe, internal-expanding type with an automatic
adjuster screw. The automatic adjuster screw is
located directly below the wheel cylinder that is
mounted near the top of the brake assembly (Fig. 9).
These and two brake shoes (and attaching parts) are
mounted to a support plate at each rear wheel. A
brake drum covers each brake assembly.
OPERATION
OPERATION - DISC BRAKES (FRONT)
When the brakes are applied, fluid pressure is sent
to each brake caliper. The pressure at the caliper is
exerted equally against the caliper piston. The pres-
sure applied to the piston is transmitted directly to
the inboard brake shoe. This forces the shoe lining
against the inner surface of the brake rotor. At the
same time, fluid pressure within the caliper piston
bore forces the caliper to slide inward on its guide
pins. This action brings the outboard shoe lining into
contact with the outer surface of the brake rotor.
This pressure on both sides of the brake rotor causes
friction, bringing the vehicle to a stop. When the brake pedal is released, so is the fluid
pressure. The piston seal inside the caliper is
designed to pull the piston back into the bore of the
caliper when the brake pedal is released (Fig. 10).
This action helps maintain the proper brake shoe-to-
rotor clearance. As disc brake shoe linings wear, master cylinder
reservoir brake fluid level will drop. Adjust as neces-
sary. Fluid level should always be checked after
replacing shoes.
Fig. 8 Rear Disc Brakes
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 9 Drum Brake Assembly (Right Shown)
1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
3 - AUTOMATIC ADJUSTER LEVER
4 - TENSION CLIP
5 - AUTOMATIC ADJUSTER ASSEMBLY
5s - 12 BRAKESRS
HYDRAULIC/MECHANICAL (Continued)

BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES 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. 11). 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. 12). (10) Repeat the above procedure on other side of
the vehicle.
REMOVAL - FRONT DISC BRAKE SHOES (TRW
BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
NOTE: Perform Step 2 through Step 5 on each side
of the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 13).
Fig. 11 Stored Front Disc Brake Caliper
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
Fig. 12 Removing Inboard Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
Fig. 13 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5s - 14 BRAKESRS

(4) Remove the disc brake caliper from the disc
brake adapter and hang out of the way using wire or
a bungee cord. Use care not to overextend the brake
hose when doing this. (5) Remove the brake shoes from the disc brake
caliper adapter.
CLEANING - DISC BRAKE SHOES
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors. If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point. ² For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced. ² For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced. ² Typically, if front shoes are worn out, both fronts
and rears need to be replaced. Make sure to check
rears. Replace
bothdisc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
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 removed from.
INSTALLATION
INSTALLATION - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES)
NOTE: There may be more than 1 lining material
released. Make sure proper linings are being
installed.
(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 Mopar tDielectric
grease, or equivalent. (6) Slide the new outboard brake shoe into the cal-
iper adapter with the lining up against the outside of
the brake rotor.
CAUTION: Use care when installing the caliper
assembly onto the caliper adapter, so the caliper
guide pin bushings do not get damaged by the
adapter 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 caps over the caliper guide pin bolts.
(10) Install the new caliper hold down spring (anti-
rattle clip) on the outboard side of the caliper. Start
the spring into the holes on the caliper, then stretch
the clip legs past the abutments on the caliper
adapter. (11) Repeat the above procedure on other side of
the vehicle.
RS BRAKES5s-15
BRAKE PADS/SHOES - FRONT (Continued)

(12) Install the wheel and tire assemblies. 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.). (13) Lower vehicle.
(14) Pump the brake pedal several times. This will
set the shoes to the brake rotor. (15) Check and adjust brake fluid level as neces-
sary. (16) 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
(TRW 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.
13). (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. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (2) Remove rear wheel and tire assemblies from
vehicle. (3) Remove the caliper to adapter guide pin bolts
(Fig. 14).
(4) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 15).
Fig. 14 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 15 Removing/Installing Caliper
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
5s - 16 BRAKESRS
BRAKE PADS/SHOES - FRONT (Continued)

(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
16).
(6) If the brake rotor needs to be removed it can be
removed by removing the retainer clips and then
pulling the rotor straight off the wheel mounting
studs. (7) Remove the outboard brake shoe from the cali-
per. Brake shoe is removed by pushing the shoe
toward the piston, disengaging the two metal protru-
sions on the shoe back, then sliding the brake shoe
off the caliper. (8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 17).
CLEANING - DISC BRAKE SHOES
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors. If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point. ² For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced. ² For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced. ² Typically, if front shoes are worn out, both fronts
and rears need to be replaced. Make sure to check
rears.
Fig. 16 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 17 Removing Inboard Brake Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
RS BRAKES5s-17
BRAKE PADS/SHOES - REAR DISC (Continued)

Replacebothdisc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
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 removed from.
INSTALLATION - REAR DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly. (2) Lubricate both adapter abutments where the
shoes contact with a liberal amount of Mopar tMul-
tipurpose Lubricant, or equivalent. (3) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub. (4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
NOTE: The outboard shoes are different left to
right. They can be identified by a L or R stamped on
the clip.
(5) Install the outboard brake shoe on the disc
brake caliper. Be sure the outboard shoe is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(6) Carefully lower caliper and brake shoes over
rotor and onto adapter, reversing the removal proce-
dure (Fig. 15).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.). (8) 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.). (9) Lower vehicle.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle. (10) Pump brake pedal several times to set brake
shoes to rotors. (11) Check fluid level in reservoir.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
BRAKE PADS/SHOES - REAR
DRUM
REMOVAL - REAR DRUM BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (2) Remove the rear wheel and tire assemblies
from the vehicle. (3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM
- REMOVAL)
NOTE: When creating slack in the park brake cables
by locking out the automatic adjuster, (Fig. 18) be
sure that the park brake pedal is in the released
(most upward) position.
(4) Create slack in the rear park brake cables.
Slack is created by grabbing exposed section of front
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake
cable just rearward of only the rearbody outrigger
bracket. (Fig. 18)
Fig. 18 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
5s - 18 BRAKESRS
BRAKE PADS/SHOES - REAR DISC (Continued)