warning CHRYSLER VOYAGER 2004 Owner's Guide

CAUTION
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoes and braking surfaces of brake rotor or drum,
and external surfaces of hub and bearing assembly.
CAUTION: Brake rotor and caliper handling must be
done in such a way as to avoid damage to the rotor,
especially the machined surfaces, and scratching or
nicking of the brake linings.
CAUTION: Only the recommended jacking or hoist-
ing procedures for this vehicle are to be usedwhenever it is necessary to lift a vehicle. Failure to
raise a vehicle utilizing the recommended lift points
can result in damage to the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING - STAN-
DARD PROCEDURE)
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON 1. Parking brake lever not fully
released. 1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever. 2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem. 5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated. 6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION 1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage. 2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing. Correct as necessary.
2. Lack of lubricant on brake caliper
slides. 2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK 1. Broken or missing anti-rattle
spring clips on shoes. 1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
5s - 4 BRAKESRS
BRAKES - BASE (Continued)

DESCRIPTION N´mFt.
Lbs. In.
Lbs.
Proportioning Valve
Mounting Bolts 54 40 Ð
Proportioning Valve Axle
Bracket Mounting Bolt 20 Ð 175
Parking Brake Lever (Pedal)
Mounting Bolts And Nut 28 21 250
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
BASE BRAKE SYSTEM
BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 3).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate: ² Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system. ² Brake shoe linings which have worn to a point
requiring replacement. As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid. If
the brake fluid level has dropped below the add
Tubes, Master Cylinder Bleed 8358
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Shoe C-3919
Handle, Universal C±4171
Installer, Dust Boot C-4689 or C-4842
RS BRAKES5s-9
BRAKES - BASE (Continued)

(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)

(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)

DISC BRAKE CALIPER -
FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES)
(1) Depress the brake pedal past its first inch of
travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
master cylinder from the brake hydraulic system dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove front wheel and tire assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper. There are two washers (one
on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers. (5) Remove the 2 caliper guide pin bolts.
(6) Remove the brake caliper from the adapter.
REMOVAL - FRONT DISC BRAKE CALIPER
(TRW BRAKES)
(1) Using a brake pedal holding tool, depress the
brake pedal past its first one inch of travel and hold
it in this position. This will isolate the master cylin-
der from the brake hydraulic system and will not
allow the brake fluid to drain out of the master cyl-
inder reservoir when the lines are opened. (2) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE. (3) Remove the front tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 31). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Discard the
washers. (5) Remove the two brake caliper guide pin bolts
(Fig. 31). (6) Remove the disc brake caliper from the disc
brake adapter.
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (CONTINENTAL TEVES BRAKES)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING or INSPECTION in
this section. (1) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss. (2) Repeat this procedure on the remaining bush-
ing.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
Fig. 31 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
RS BRAKES5s-23

master cylinder reservoir from completely draining
out.(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws. (5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 32). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth. (8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.CLEANING - CALIPER
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.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or Mopar tNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
² Brake fluid leaks in and around boot area and
inboard lining ² Ruptures, brittleness or damage to the piston
dust boot ² Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
(CONTINENTAL TEVES BRAKES)
(1) Fold the guide pin bushing in half lengthwise.
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing. (2) Insert the folded bushing into the caliper
mounting boss using your fingers from the rear of
the caliper.
Fig. 32 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
5s - 24 BRAKESRS
DISC BRAKE CALIPER - FRONT (Continued)

(1) Depress the brake pedal past its first inch of
travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
master cylinder from the brake hydraulic system dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (3) Remove rear wheel and tire assembly from
vehicle. (4) Remove the banjo bolt connecting the brake
hose to the brake caliper. There are two washers (one
on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers. (5) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 36).
(6) 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. 37). (7) If the brake rotor requires removal, it can now
be removed by first removing the retainer clips from
the wheel mounting studs, then pulling the rotor
straight off the studs.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out. (3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws. (5) Remove the piston dust boot from the caliper
and discard.
Fig. 36 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 37 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
RS BRAKES5s-27
DISC BRAKE CALIPER - REAR (Continued)

NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 38). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth. (8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.
CLEANING - CALIPER
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.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or Mopar tNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
² Brake fluid leaks in and around boot area and
inboard lining ² Ruptures, brittleness or damage to the piston
dust boot ² Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY - CALIPER PISTON AND SEAL
NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid
and install it in the groove of the caliper bore. The
seal should be started at one area of the groove and
gently worked around and into the groove (Fig.
39)using only your clean fingers to seat it. (2) Coat the new piston boot with clean brake
fluid. (3) Position the dust boot over the piston after
coating it with brake fluid.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 40). (5) Position the dust boot into the counterbore of
the caliper assembly piston bore. (6) Using a hammer and Installer, Special Tool
C-4689 or C-4842 (depending on piston size), and
Handle, Special Tool C-4171, drive the boot into the
counterbore of the caliper as necessary (Fig. 41).
Fig. 38 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
5s - 28 BRAKESRS
DISC BRAKE CALIPER - REAR (Continued)

CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
48). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.). (5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
48). (6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopar t
Brake Fluid or equivalent. (11) Road test vehicle to ensure proper operation of
brakes.
INSTALLATION - RHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting. (2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston. (3) Install the two master cylinder mounting nuts
(Fig. 50). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion. (4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
50). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.). (5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
46). (6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopar t
Brake Fluid or equivalent. (11) Road test vehicle to ensure proper operation of
brakes.
PEDALS - ADJUSTABLE
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Move driver's seat to full rearward position.
(2) Disconnect negative battery cable from battery
post and isolate. (3) Remove throttle cable from throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL) (4) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 53). (5) Disconnect parking brake release link at
release handle. (6) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate. (7) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 53). (8) Remove hood release from lower left reinforce-
ment. (9) Remove screws securing instrument panel
lower left reinforcement in place, then remove rein-
forcement (Fig. 54). (10) Remove brake lamp switch. Discard original
switch; it must not be reused. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL) (11) Remove upper and lower steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - REMOVAL)
5s - 38 BRAKESRS
MASTER CYLINDER (Continued)

CABLES - PARKING BRAKE
(EXPORT)
REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE
(Refer t o 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 t o 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. 110).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable. (10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(11) Remove the lower bolt mounting the park
brake pedal to the body (Fig. 111). (12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 111). (13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 111).
(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block. (15) Remove park brake pedal release link from
park brake mechanism. (16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
111). (17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism. (2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket. (3) Install cable strand button into the clevis on
the park brake pedal mechanism. (4) Install wiring harness connector on warning
indicator lamp ground switch.Fig. 110 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
Fig. 111 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RS BRAKES5s-67