sensor CHRYSLER VOYAGER 2004 Owner's Manual

punch and tap edge of sensor ear, rocking the sensor
side-to-side until free.
(8) Remove front wheel speed sensor from vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts and
over extension of cables, resulting in an open cir-
cuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector. Be sure speed
sensor cable connector is fully seated and locked into
vehicle wiring harness connector.
(2) Install the bolts attaching the routing clamps
to the body of the vehicle. Tighten the bolts to a
torque of 14 N´m (125 in. lbs.).
(3) Insert speed sensor cable grommets into inter-
mediate bracket on strut.
(4) Install the wheel speed sensor head mounting
bolt (Fig. 1). Tighten the bolt to a torque of 13 N´m
(115 in. lbs.)
(5) Install the wheel and tire assembly on vehicle.
(6) Lower vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
REAR WHEEL SPEED SENSOR
-AWD
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness.
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips along brake hose and tubing.(4) Remove bolt securing wheel speed sensor cable
metal clip to rear of axle. Remove metal clip from
cable if necessary.
CAUTION: If speed sensor head has seized due to
corrosion, do not use pliers on speed sensor head
in an attempt to remove it. Use a hammer and a
punch and tap mounting flange edge side-to-side,
rocking the sensor until free.
(5) Remove wheel speed sensor head attaching
bolt.
(6) Remove wheel speed sensor head from the axle,
and remove sensor from vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as indicated may
result in contact with moving parts or over-exten-
sion of cables, resulting in an open circuit.
(1) Install wheel speed sensor head in axle flange.
CAUTION: Prior to installing the speed sensor head
attaching bolt, the plastic anti-rotation pin must be
fully seated into the bearing flange.
(2) Install wheel speed sensor head attaching bolt.
Tighten bolt to a torque 10 N´m (90 in. lbs.).
(3) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone
wheel. (Refer to 5 - BRAKES - SPECIFICATIONS)
CAUTION: When installing wheel speed sensor
cable in the routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake hose if damaged.
(4) Install speed sensor cable under leaf spring
onto brake hose and tubing utilizing routing clips to
secure it in place.
(5) Install metal routing clip on speed sensor cable
and mount it to rear of axle with mounting bolt.
Tighten mounting bolt to 16 N´m (140 in. lbs.).
(6) Connect wheel speed sensor cable to vehicle
wiring harness.Be sure speed sensor cable con-
nector is fully seated and locked into vehicle
wiring harness connector.
(7) Install speed sensor cable grommet into the
floor pan, being sure the grommet is fully seated into
the access hole.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
5 - 80 BRAKES - ABSRS
FRONT WHEEL SPEED SENSOR (Continued)

REAR WHEEL SPEED SENSOR
- FWD
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness (Fig. 2).
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips (Fig. 3).
(4) Remove bolt securing metal routing clip to rear
of axle and remove sensor cable from metal clip (Fig.
3).
(5) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 4).
(6) Push up on metal retaining clip (Fig. 4) until it
bottoms. This will release wheel speed sensor head
from hub and bearing. While holding metal clip up,
pull back on wheel speed sensor head removing it
from hub and bearing.(7) Remove wheel speed sensor assembly from
vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cable is critical to continued system operation.
Be sure that cable is installed in routing retainers/
clips. Failure to install cable in retainers may result
in contact with moving parts or over extension of
cable, resulting in an open circuit.
Fig. 2 Wheel Speed Sensor Connector
1 - CONNECTOR
2 - FLOOR PAN
3 - GROMMET
Fig. 3 SPEED SENSOR CABLE ROUTING
1 - METAL CLIP AND MOUNTING BOLT
2 - ROUTING CLIPS
Fig. 4 SENSOR CONNECTION AT HUB AND
BEARING
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
RSBRAKES - ABS5-81

NOTE: Make sure wheel speed sensor stays clean
and dry as it is installed into the hub and bearing
cap.
(1) If metal sensor retaining clip is not in the neu-
tral installed position on hub and bearing cap, install
from the bottom, if necessary, and push clip upward
until it snaps into position.
(2) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch in
the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining clip.
(3) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on each
side.
(4) Route sensor cable under leaf spring along rear
of axle. Install speed sensor cable into routing clips
on rear brake flex hose (Fig. 3).
(5) Install cable into metal routing clip and attach
it to the rear axle with mounting bolt (Fig. 3).
Tighten mounting bolt to 16 N´m (140 in. lbs.).
(6) Connect wheel speed sensor cable to vehicle
wiring harness (Fig. 2).Be sure speed sensor
cable connector is fully seated and locked into
vehicle wiring harness connector.
(7) Install speed sensor cable grommet into hole in
floor pan making sure grommet is fully seated into
hole.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
TONE WHEEL
INSPECTION - TONE WHEEL
NOTE: Rear tone wheels for front-wheel-drive vehi-
cles are sealed within the hub and bearing assem-
bly and cannot be inspected or replaced.
Replacement of the hub and bearing is necessary.
Tone wheels can cause erratic wheel speed sensor
signals. Inspect tone wheels for the following possible
causes.
²missing, chipped, or broken teeth
²contact with the wheel speed sensor
²wheel speed sensor to tone wheel alignment
²wheel speed sensor to tone wheel clearance
²excessive tone wheel runout
²tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement,
the drive shaft must be replaced. No attempt should
be made to replace just the tone wheel. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL)If a rear tone wheel is found to need replacement
on an all-wheel-drive model, the drive shaft must be
replaced. No attempt should be made to replace just
the tone wheel. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/HALF SHAFT - REMOVAL)
If wheel speed sensor to tone wheel contact is evi-
dent, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and
the tone wheel to ensure it is within specifications.
(Refer to 5 - BRAKES - ABS/ELECTRICAL - SPEC-
IFICATIONS)
Excessive wheel speed sensor runout can cause
erratic wheel speed sensor signals. Refer to SPECI-
FICATIONS in this section of the service manual for
the maximum allowed tone wheel runout (Refer to 5 -
BRAKES - ABS/ELECTRICAL - SPECIFICATIONS).
If tone wheel runout is excessive, determine if it is
caused by a defect in the driveshaft assembly or hub
and bearing. Replace as necessary.
Tone wheels are pressed onto their mounting sur-
faces and should not rotate independently from the
mounting surface. Replacement of the front drive-
shaft, rear driveshaft (AWD only) or rear hub and
bearing is necessary.
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH
(1) Remove lower column shroud.
(2) Disconnect traction control switch harness from
column harness below column.
(3) Using an ohmmeter, check for continuity read-
ing between pins. Refer to TRACTION CONTROL
SWITCH CONTINUITY test table and (Fig. 5).
TRACTION CONTROL SWITCH CONTINUITY
SWITCH POSITION CONTINUITY BETWEEN
ACTUATED PINS 1 AND 2
ILLUMINATION PINS 1 AND 3
Fig. 5 TRACTION CONTROL SWITCH CONNECTOR
5 - 82 BRAKES - ABSRS
REAR WHEEL SPEED SENSOR - FWD (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT) 1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe support plate where shoes ride. 1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined braking surface. 1. Replace brake drums as necessary.
DRUM BRAKE HOWL OR
MOAN 1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor. 1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING 1. ABS wheel speed sensor or tone
wheel. 1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL). 1. Foreign object interference with
brakes. 1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or disc brake rotor has excessive
thickness variation. 1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL) 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent. 5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY) 1. Parking brake cables binding or
froze up. 1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes. 2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only). 3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted. Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes. Repair source of contamination.
2. Improper power brake booster
assist. 2. Refer to power brake booster
diagnosis and testing.
RS
BRAKES5s-5
BRAKES - BASE (Continued)

PRESSURE BLEEDING PROCEDURE
CAUTION: Use bleeder tank Special Tool C-3496-B
or equivalent with Adapter, Special Tool 6921, to
pressurize the hydraulic system for bleeding.Follow pressure bleeder manufacturer's instruc-
tions for use of pressure bleeding equipment. (1) Install the Adapter Master Cylinder Pressure
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 2). Attach the fluid hose
from the pressure bleeder to the fitting on Special
Tool 6921.
(2) Attach a clear plastic hose to the bleeder screw
at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid. (3) Open the left rear wheel bleeder screw at least
one full turn or more to obtain an adequate flow of
brake fluid.
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.
(4) After 4 to 8 ounces of brake fluid has been bled
through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate a
good bleed of the hydraulic system has been
obtained. (5) Repeat the procedure at all the other remain-
ing bleeder screws. (6) 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. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) 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.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´m Ft.
Lbs. In.
Lbs.
ABS ICU Mounting Bolts To
Bracket 11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts 28 21 250
ABS CAB-To-HCU Mounting
Screws 2Ð17
ABS Wheel Speed Sensor
Head Mounting Bolt - Front 13 Ð 115
ABS Wheel Speed Sensor
Head Mounting Bolt - Rear 10 Ð 90
Adjustable Pedal Position
Sensor Mounting Screws 7.5 66 Ð
Adjustable Pedal Module
Mounting Screws 2.0 15 Ð
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt 12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt 47 35 Ð
Disc Brake Caliper Guide
Pin Bolts 35 26 Ð
Disc Brake Caliper Bleeder
Screw 15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts 8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw 10 Ð 80
Drum Brake Support Plate
Mounting Bolts 130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts 28 21 250
Master Cylinder Mounting
Nuts 25 19 225
Power Brake Booster
Mounting Nuts 28 21 250
Fig. 2 Tool 6921 Installed On Master Cylinder
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
5s - 8 BRAKESRS
BRAKES - BASE (Continued)

(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer t o 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 t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (10) Install brake drum.
(11) 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.). (12) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS) (13) Remove brake pedal depressor tool.
(14) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE). (15) Lower the vehicle.
WHEEL CYLINDERS
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
(Discard if contaminated).(Refer t o 5 - BRAKES/HY-
DRAULIC/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.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
Fig. 92 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. 93 Brake Support Plate Mounted On BearingAttaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
RS BRAKES5s-59
SUPPORT PLATE - DRUM BRAKE (Continued)

(16) AWD only - Remove ABS wheel speed sensor
head from hub/bearing (Fig. 123).
(17) FWD only - Remove the ABS wheel speed sen-
sor from the hub/bearing in the following fashion: (a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 124). (b) Push up on metal retaining clip (Fig. 124)
until it bottoms. This will release wheel speed sen-
sor head from hub and bearing. While holding
metal clip up, pull back on wheel speed sensor
head removing it from hub and bearing. (c) Remove wheel speed sensor from hub/bear-
ing. (18) Remove the hub/bearing-to-axle mounting
bolts (Fig. 125).
(19) Remove the hub/bearing (Fig. 126).
Fig. 123 Speed Sensor Attaching Bolt (AWD)
1 - ADAPTER
2 - TONE WHEEL
3 - WHEEL SPEED SENSOR
4 - AXLE
5 - BOLT
6 - DRIVESHAFT
Fig. 124 Sensor Connection At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 125 Hub/Bearing Mounting Bolts (AWD Shown)
1 - DRIVESHAFT
2 - MOUNTING BOLTS
3 - AXLE
4 - MOUNTING BOLTS
5 - ADAPTER
Fig. 126 Hub/Bearing Removal/Installation (AWD Shown)
1 - PARK BRAKE BRAKE SHOE
2 - OUTER C/V JOINT
3 - HUB/BEARING
4 - PARK BRAKE BRAKE SHOE
5 - STUB SHAFT
5s - 72 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(27) Remove the hold down spring and pin (Fig.
134) from the trailing park brake shoe.
(28) Remove the trailing park brake shoe from the
adapter. (29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (3) Install the hold down spring and pin (Fig. 134)
on the trailing park brake shoe. (4) Install the upper return springs (Fig. 133) on
the trailing park brake shoe. (5) Install the upper return springs on the leading
park brake shoe (Fig. 132). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter. (6) Install the adjuster (Fig. 131) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (7) Install the hold down spring and pin (Fig. 130)
on the leading park brake shoe. (8) Install the lower return spring (Fig. 129) on
the leading and trailing park brake shoes. When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 129). (9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle. (10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 135).
(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 126). (12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.). (13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 123). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs). (14) FWD only - Install the wheel speed sensor in
the following fashion: (a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
Fig. 134 Trailing Brake Shoe Hold Down Pin And Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
Fig. 135 Adapter Installed On Mounting Bolts (AWD Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
RS BRAKES5s-75
SHOES - PARKING BRAKE (Continued)

(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.
(15) Install the park brake cable into its mounting
hole in the adapter. Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter. (16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 121). (17) Attach park brake cable to adapter using
mounting bolt. (18) Remove the locking pliers (Fig. 117) from the
front park brake cable. (19) Adjust the park brake drum-in-hat brake
shoes. (Refer t o 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS). (20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 119).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 118).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.). (23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 116) on the stub shaft of
the outer C/V joint. (24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.). (26) AWD only - Install the spring washer (Fig.
115) on the stub shaft of the outer C/V joint. (27) AWD only - Install the nut retainer and cotter
pin (Fig. 114) on the stub shaft of the outer C/V joint. (28) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.). (29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum. (5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent, accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
137). (6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 138).
Fig. 136 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 76 BRAKESRS
SHOES - PARKING BRAKE (Continued)

STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 6) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
For cooling system capacity, (Refer to LUBRICATION
& MAINTENANCE/FLUID CAPACITIES - SPECIFI-
CATIONS).
Fill coolant recovery/reserve container (Fig. 6) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 6). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 6). The
coolant level should be between the MIN and MAX
marks.
SPECIFICATIONS
ACCESSORY DRIVE BELT TENSION
ACCESSORY DRIVE BELT TENSION
2.4L ENGINE
Air Conditioning
Compressor/GeneratorDynamic Tensioner
Power
SteeringNew Belt534 - 756 N
(120 - 170 lbs.)
Used Belt*356 - 534 N
(80 - 120 lbs)
*Belt is considered used after 15 minutes of run-in
time
3.3/3.8L ENGINES
Air Conditioning Compressor
Dynamic Tensioner
Generator/Water Pump/
Power Steering
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Accessory Drive Belt Tensioner
Assembly (3.3/3.8L)ÐBolt28 Ð 250
Engine Coolant Temperature
Sensor
(2.4 & 3.3/3.8L) 7 Ð 60
Generator & A/C Compressor
Drive Belt Tensioner Assembly
(2.4L)ÐBolt54 40 Ð
Coolant Outlet Connector/
Thermostat Housing
(2.4 & 3.3/3.8L)ÐBolts 28 Ð 250
Water Pump
(2.4 & 3.3/3.8L)ÐBolts 12 Ð 105
Water Pump Inlet Tube
(2.4L)ÐBolts12 Ð 105
Water Pump Inlet Tube
(3.3/3.8L)ÐBolts28 Ð 250
Water Pump Pulley (3.3/3.8L)Ð
Bolts28 Ð 250
Radiator to A/C CondenserÐ
Screws5Ð45
Radiator FanÐScrews 5 Ð 45
Radiator Mounting (Upper
Bracket)ÐNuts12 Ð 105
RSCOOLING7-5
COOLING (Continued)