steering wheel CHRYSLER VOYAGER 2004 Workshop Manual

START-UP CYCLE
When the ignition is turned on, a popping sound
and a slight brake pedal movement may be noticed.
The ABS warning lamp will also be on for up to 5
seconds after the ignition is turned on. When the
vehicle is first driven off, a humming may be heard
or felt by the driver at approximately 20±40 kph
(12±25 mph). All of these conditions are a normal
function of ABS as the system is performing a diag-
nosis check.
PREMATURE ABS CYCLING
Symptoms of premature ABS cycling include: click-
ing sounds from the solenoid valves; pump/motor
running; and pulsations in the brake pedal. Prema-
ture ABS cycling can occur at any braking rate of the
vehicle and on any type of road surface. Neither the
red BRAKE warning lamp, nor the amber ABS warn-
ing lamp, illuminate and no fault codes are stored in
the CAB.
Premature ABS cycling is a condition that needs to
be correctly assessed when diagnosing problems with
the antilock brake system. It may be necessary to use
a DRB scan tool to detect and verify premature ABS
cycling.
Check the following common causes when diagnos-
ing premature ABS cycling: damaged tone wheels;
incorrect tone wheels; damaged steering knuckle
wheel speed sensor mounting bosses; loose wheel
speed sensor mounting bolts; excessive tone wheel
runout; or an excessively large tone wheel-to-wheel
speed sensor air gap. Give special attention to these
components when diagnosing a vehicle exhibiting
premature ABS cycling.
After diagnosing the defective component, repair or
replace it as required. When the component repair or
replacement is completed, test drive the vehicle to
verify that premature ABS cycling has been cor-
rected.
OPERATION - ELECTRONIC VARIABLE BRAKE
PROPORTIONING
Upon entry into EVBP the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure, the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
hydraulic control unit (HCU) resulting in a drop in
fluid pressure to the rear brakes. In order to increase
the rear brake pressure, the outlet valve is switched
off and the inlet valve is pulsed. This increases the
pressure to the rear brakes. This back-and-forth pro-
cess will continue until the required slip difference is
obtained. At the end of EVBP braking (brakes
released) the fluid in the LPA drains back to themaster cylinder by switching on the outlet valve and
draining through the inlet valve check valve. At the
same time the inlet valve is switched on in case of
another brake application.
The EVBP will remain functional during many
ABS fault modes. If both the red BRAKE and amber
ABS warning indicators are illuminated, the EVBP
may not be functioning.
OPERATION - TRACTION CONTROL SYSTEM
The traction control module monitors wheel speed.
During acceleration, if the module detects front
(drive) wheel slip and the brakes are not applied, the
module enters traction control mode. Traction control
operation proceeds in the following order:
(1) Close the normally open isolation valves.
(2) Start the pump/motor and supply volume and
pressure to the front (drive) hydraulic circuit. (The
pump/motor runs continuously during traction con-
trol operation.)
(3) Open and close the build and decay valves to
maintain minimum wheel slip and maximum trac-
tion.
The cycling of the build and decay valves during
traction control is similar to that during antilock
braking, except the valves work to control wheel spin
by applying the brakes, whereas the ABS function is
to control wheel skid by releasing the brakes.
If the brakes are applied at anytime during a trac-
tion control cycle, the brake lamp switch triggers the
controller to switch off traction control.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves allow
pressure and volume to return to the master cylinder
reservoir when not consumed by the build and decay
valves. These valves are necessary because the
pump/motor supplies more volume than the system
requires.
TRACTION CONTROL LAMP
The traction control system is enabled at each igni-
tion cycle. It may be turned off by depressing the
Traction Control Off switch button when the ignition
is in the ON position. The traction control function
lamp (TRAC OFF) illuminates immediately upon
depressing the button.
The traction control function lamp illuminates dur-
ing a traction control cycle, displaying TRAC.
If the CAB calculates that the brake temperatures
are high, the traction control system becomes inoper-
ative until a time-out period has elapsed. During this
ªthermo-protection mode,º the traction control func-
tion lamp illuminates TRAC OFF; note that no trou-
ble code is registered.
RSBRAKES - ABS5-77
BRAKES - ABS (Continued)

BLEEDING
When bleeding the ABS system, the following
bleeding sequence must be followed to insure com-
plete and adequate bleeding.
(1) Make sure all hydraulic fluid lines are installed
and properly torqued.
(2) Connect the DRBIIItscan tool to the diagnos-
tics connector. The diagnostic connector is located
under the lower steering column cover to the left of
the steering column.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does, clear
them using the DRB.
WARNING:
WHEN BLEEDING THE BRAKE SYSTEM
WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS
AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE
FLOW OF BRAKE FLUID AWAY FROM YOURSELF
AND THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME OUT
OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure. (Refer
to 5 - BRAKES - BASE - STANDARD PROCEDURE)
(5) Using the DRB, select ANTILOCK BRAKES,
followed by MISCELLANEOUS, then BLEED
BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, discon-
nect the scan tool and proceed.
(6) Bleed the base brake system a second time.
Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the hydrau-
lic system.
(7) Fill the master cylinder reservoir to the full
level.
(8) Test drive the vehicle to be sure the brakes are
operating correctly and that the brake pedal does not
feel spongy.
SPECIFICATIONS
ABS FASTENER TORQUE
(Refer to 5 - BRAKES - BASE - SPECIFICA-
TIONS)
TONE WHEEL RUNOUT
DESCRIPTION SPECIFICATION
Front Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
Rear Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
WHEEL SPEED SENSOR AIR GAP
DESCRIPTION SPECIFICATION
Front Sensor0.35 ± 1.20 mm
0.014 ± 0.047 in.
Rear Sensor0.40 ± 1.20 mm
0.016 ± 0.047 in.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly.
(3) Remove the sensor cable routing clamp screws.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Remove speed sensor cable grommets from
intermediate bracket on strut.
(5) Disconnect speed sensor cable from vehicle wir-
ing harness behind fender well shield.
(6) Remove the wheel speed sensor head mounting
bolt (Fig. 1).
(7) Remove sensor head from steering knuckle. If
sensor has seized due to corrosion,DO NOT USE
PLIERS ON SENSOR HEAD.Use a hammer and a
Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - DRIVESHAFT
4 - TONE WHEEL
5 - STEERING KNUCKLE
RSBRAKES - ABS5-79
BRAKES - ABS (Continued)

(10) Disconnect the 24±way connector from the
CAB. To disconnect the 24±way connector, grasp the
lock on the 24±way connector and pull it as far up as
possible. This will unlock the 24±way connector from
the socket on the CAB.
CAUTION: Before removing the brake tubes from
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(11) Thoroughly clean all surfaces of the ICU and
brake tube nuts. Use only a solvent such as Mopart
Brake Parts Cleaner or equivalent to clean the ICU.
(12) Remove the brake tubes (4) from the outlet
ports on the HCU (Fig. 14).
(13) Remove the primary and secondary brake
tubes from the inlet ports on the HCU (Fig. 14).
(14) Center and prop the steering wheel.
(15) Remove the pinch bolt and disconnect the
steering shaft coupling.
(16) If equipped, remove the two clips securing
silencer to dash seal (Fig. 15). Remove silencer.
(17) Remove the three screws securing the dash
seal (Fig. 15). Remove seal.
(18) Remove the 3 bolts attaching the ICU to its
mounting bracket (Fig. 16).
(19) Remove ICU from the vehicle through engine
compartment.
(20) If required, to separating the CAB from the
HCU, (Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
DISASSEMBLY).
REMOVAL - RHD
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION)
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
Fig. 14 Brake Tube Nuts At ICU
1 - PRIMARY BRAKE TUBE
2 - SECONDARY BRAKE TUBE
3 - CHASSIS BRAKE TUBES
Fig. 15 Lower Coupling And Dash Seal
1 - COUPLING
2 - DASH SEAL
3 - SILENCER
4 - MOUNTING SCREWS
5 - RETAINING CLIPS
6 - DASH
Fig. 16 ICU Mounting Bolts
1 - ICU MOUNTING BOLTS
2 - COUPLER
RSBRAKES - ABS5-91
ICU (INTEGRATED CONTROL UNIT) (Continued)

ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact eachother or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 94 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (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

INSTALLATION
INSTALLATION - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system. If
calipers are interchanged, improper performance,
noise and increased stopping distance can occur.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL -
DESCRIPTION)
(1) Completely retract the caliper piston back into
piston bore of the caliper. Use a C-clamp to retract
the piston if necessary. Place a wood block over the
piston before installing the C-clamp to avoid damag-
ing the piston.
CAUTION: Use care when installing the brake cali-
per assembly onto the steering knuckle, so that the
seals on the caliper guide pin bushings do not get
damaged by the steering knuckle bosses.
(2) Carefully position the brake caliper and shoes
over the brake rotor and adapter. (3) 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. (4) Install the anti-rattle clip on the outboard side
of the caliper. Start the clip into the holes on the cal-
iper, then stretch the clip legs past the abutments on
the caliper adapter.
CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
copper washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special fitting washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N´m (35 ft.
lbs.). (6) 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.). (7) Lower the vehicle.
(8) Remove the brake pedal depressor (holding)
tool. (9) Bleed the hydraulic brake circuit to the brake
caliper. (Refer t o 5 - BRAKES - STANDARD PROCE-
DURE) (10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
INSTALLATION - FRONT DISC BRAKE CALIPER
(TRW BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system. If
calipers are interchanged, improper performance,
noise and increased stopping distance can occur.
(Refer t o 5 - BRAKES/HYDRAULIC/MECHANICAL -
DESCRIPTION)
(1) Completely retract the caliper piston back into
the bore of the caliper. Use a C-clamp to retract the
piston if necessary. Place a wood block over the pis-
ton before installing the C-clamp to avoid damaging
the piston.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(2) Install the disc brake caliper over the brake
shoes on the brake caliper adapter. (3) 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.
31). (4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 31). Install NEW copper
washers on each side of the hose fitting as the banjo
bolt is guided through the fitting. Thread the banjo
bolt into the caliper and tighten it to a torque of 47
N´m (35 ft. lbs.). (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) Remove the brake pedal holding tool.
(8) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - BASE - STANDARD PROCEDURE). (9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER
NOTE: Handling of the rotor and caliper, must be
done in such a way as to avoid damage to the rotor
and scratching or nicking of lining on the brake
shoes.
5s - 26 BRAKESRS
DISC BRAKE CALIPER - FRONT (Continued)

specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).(8) Lower the vehicle.
(9) Remove the brake pedal depressor (holding)
tool. (10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer t o 5 - BRAKES - STANDARD PROCE-
DURE) (11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
DISC BRAKE CALIPER
ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (2) Remove front wheel and tire assembly, disc
brake caliper and brake shoes. (Refer t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL) (3) Remove two bolts fastening adapter to steering
knuckle, then remove disc brake caliper adapter.
INSTALLATION - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Place adapter over brake rotor and align
adapter mounting holes to knuckle.
CAUTION: Adapter mounting bolts have a special
Dacromet Tcoating applied to resist corrosion. If
mounting bolts need to be replaced, use only
Mopar Treplacement parts.
(2) Install adapter mounting bolts and tighten to
169 N´m (125 ft. lbs.) torque. (3) Install brake shoes, disc brake caliper and
wheel and tire assembly. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
INSTALLATION) (4) Lower vehicle.
(5) Pump the brake pedal several times to set the
pads to the brake rotor. (6) Check and adjust brake fluid level as neces-
sary.
DISC BRAKE CALIPER GUIDE
PINS
REMOVAL - DISC BRAKE CALIPER GUIDE PINS
(TRW BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE. (2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 42).
(4) Remove the disc brake caliper from the disc
brake caliper adapter and hang it out of the way
using wire or a bungee cord. Use care not to overex-
tend the brake hose when doing this. (5) Remove the guide pins and boots from the
adapter as shown (Fig. 43).
INSTALLATION - DISC BRAKE CALIPER GUIDE
PINS (TRW BRAKES)
(1) Lubricate the guide pins and inside the boots
with the packet supplied with the service kit, Syth-
eso GLK-1 lubricant or equivalent. (2) Install the guide pins and boots in the adapter
as shown (Fig. 43). The boots have grooves built into
their inner lips to fit onto the pins and adapter.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
Fig. 42 Brake Caliper Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5s - 30 BRAKESRS
DISC BRAKE CALIPER - REAR (Continued)

Use only brake fluid that was stored in a tightly-
sealed container. DO NOT use petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only Mopar tBrake
Fluid or equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is located
on the driver's side of the front suspension cradle/
crossmember below the master cylinder (Fig. 44).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block. (2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following: (a) Disconnect the battery positive cable.
(b) Remove the battery (Refer t o 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). (c) Disconnect the vacuum hose connector at the
tank built into the battery tray. (d) Remove the screw securing the coolant filler
neck to the battery tray. (e) Remove the battery tray (Refer t o 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system. (4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 44). (5) Remove the primary and secondary brake
tubes from the top of the junction block. (6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.). (2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
5s - 32 BRAKESRS
FLUID (Continued)

(12) Disconnect wiring harness connectors (as
equipped) from clockspring, multi-function switch,
SKIM module, ignition switch and BTSI solenoid. (13) If equipped, disconnect PRNDL cable from
shift lever and column bracket (Fig. 55). (14) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 55). (15) Remove pinch side clip, then remove shift
cable from bracket on column. (16) Place front wheels in STRAIGHT-AHEAD
position, then secure steering wheel to column in this
position using appropriate retaining method. (17) Remove pinch bolt securing column coupling
to intermediate shaft (Fig. 56).
(18) Loosen two lower steering column mounting
nuts. (19) Remove two upper steering column mounting
nuts. (20) Remove steering column assembly.
(21) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 57).
Fig. 53 Lower Steering Column Cover And Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 54 Instrument Panel Lower Left Reinforcement
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT
Fig. 55 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE (IF EQUIPPED)
5 - STEERING COLUMN
Fig. 56 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
RS BRAKES5s-39
PEDALS - ADJUSTABLE (Continued)

(3) Install two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash panel. Do not fully tighten at this time.
(4) Install four nuts attaching pedals assembly and
power brake booster to dash panel (Fig. 61). (5) Tighten four booster mounting nuts and two
upper mounting bolts to 28 N´m (21 ft. lbs.) torque. (6) Route pedal adjuster cable up and over right
side of pedals assembly and steering column bracket, then down through hole in steering column bracket
as shown (Fig. 60). Attach end of cable to gear box.
(7) Place adjuster cable through loop on right side
of steering column bracket as shown (Fig. 60). (8) Install booster input rod onto brake pedal pin
and install a NEW retaining clip. (9) Connect wiring connector connecting vehicle
wiring harness to pedal wiring harness (Fig. 58). (10) Connect routing clips retaining vehicle wiring
harness to pedal wiring harness (Fig. 58). (11) Install brake lamp switch bracket on pedals
assembly. Tighten mounting nuts to 6 N´m (50 in.
lbs.) torque. (12) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
57). (13) Install steering column onto lower mounting
studs with nuts started, then install column onto
upper mounting studs and install two upper mount-
ing nuts. Tighten upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque. (14) Install column shaft coupling onto intermedi-
ate shaft and install pinch bolt. Make sure rounded
side of intermediate shaft is matched to the curva-
ture of the coupling. Tighten pinch bolt to 28 N´m
(250 in. lbs.) torque. (15) Remove retainer holding steering wheel in
place on steering column. (16) Attach shift cable to bracket on column.
(17) Connect shift cable end to shift lever mecha-
nism pin (Fig. 55). (18) If equipped, connect PRNDL cable to end of
shift lever mechanism pin and column bracket (Fig.
55). (19) Connect column wiring harness connectors (as
equipped) to SKIM, BTSI solenoid, ignition switch,
multi-function switch, and clockspring. (20) Install lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - INSTALLATION)
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.
(21) Install and adjust NEW brake lamp switch.
(Refer t o 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION) (22) Install instrument panel lower left reinforce-
ment (Fig. 54). (23) Attach hood release to lower left reinforce-
ment.
Fig. 60 Drive Cable Routing
1 - ADJUSTER CABLE
2 - ROUTING LOOP
3 - CABLE ATTACHMENT AT MOTOR
4 - GEAR DRIVE
5 - CABLE ATTACHMENT AT GEAR BOX
6 - STEERING COLUMN BRACKET
Fig. 61 Booster Mounting (Typical)
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
RS BRAKES5s-41
PEDALS - ADJUSTABLE (Continued)