park CHRYSLER VOYAGER 2004 Manual PDF

(6) To remove parking brake cable housing from
the body bracket, slide a 14 mm box end wrench over
retainer end compressing the three fingers (Fig. 108).
Alternate method is to use an aircraft type hose
clamp.
(7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL). (8) Disconnect parking brake cable from parking
brake actuator lever. (9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 109).
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.
99). 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. 98). (9) Manually reset the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES - STANDARD PRO-
CEDURE).
Fig. 107 Parking Brake Cables At Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 108 Parking Brake Cable Removal From Body Bracket
1 - LEFT REAR PARK BRAKE CABLE
2 - BODY BRACKET
3 - LEAF SPRING MOUNTING BRACKET
4 - CABLE RETAINER
5 - 14MM BOX WRENCH
Fig. 109 Removing Parking Brake Cable From BrakeSupport Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
RS BRAKES5s-65
CABLES - PARKING BRAKE (Continued)

(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 97). (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. 100) (Fig. 101). (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. 101). (5) Install the intermediate park brake cable on
the cable equalizer (Fig. 100). (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 t o 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. 103). (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.
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 t o 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. 107). (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 t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer t o 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.
5s - 66 BRAKESRS
CABLES - PARKING BRAKE (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

(5) Install the park brake release rod on the
release mechanism of the park brake pedal. (6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle. (7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 111). (8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 111). (9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 111). (10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.). (11) Verify that the park brake pedal is in the fully
released (full up) position. (12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 110).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer t o 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism. (16) Install the electrical junction block on the
instrument panel. (17) Install the reinforcement on the lower instru-
ment panel. (18) Install the steering column lower cover on the
lower instrument panel. (19) Install the silencer panel under the instru-
ment panel. (20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door. (22) Install the negative (ground) cable on the bat-
tery. (23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (2) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 112).
(3) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 113).
(4) Remove the equalizer from the front parking
brake cable. (5) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever mechanism to rotate around to
its stop and remove the tension from the adjuster
and front park brake cable.
Fig. 112 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 113 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
5s - 68 BRAKESRS
LEVER - PARKING BRAKE (Continued)

(6) Remove the front parking brake cable housing
from body outrigger bracket. Cable is removable by
sliding a 14 mm box wrench over the cable retainer
and compressing the three retaining fingers. Alter-
nate method: Use an aircraft type hose clamp and
screwdriver. (7) Remove the four mounting nuts from the bot-
tom of the parking brake lever bracket. (8) Lower vehicle.
(9) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL) (10) If equipped with a manual transaxle, remove
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- REMOVAL) (11) Unhook the end of the parking brake cable
from the lever mechanism. (12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers. (13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment. (14) Lift the parking brake lever and slide the
parking brake cable out. (15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle. (2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket. (3) Hook the end of the parking brake cable on the
parking brake lever mechanism. (4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan. (5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION) (6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION) (7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place. (9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place. (10) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 113). (12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables. (13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake. The park-
ing brake is set to keep the hub/bearing and
axle shaft from rotating when loosening the
hub nut. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove the wheel and tire assembly.
(4) AWD only - Remove the cotter pin and nut
retainer (Fig. 114) from the stub shaft of the outer
C/V joint.
Fig. 114 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RS BRAKES5s-69
LEVER - PARKING BRAKE (EXPORT) (Continued)

(5) AWD only - Remove the spring washer (Fig.
115) from the stub shaft of the outer C/V joint.
(6) AWD only - Remove the hub nut and washer
(Fig. 116) from the stub shaft of the outer C/V joint.
(7) Release the parking brake. (8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 117).
(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 118).
Fig. 115 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 116 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 117 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 118 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 70 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(10) Remove rear caliper from adapter using the
following 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. 119).
(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
120).
(12) Remove the rotor from the hub/bearing.
(13) Remove the park brake cable mounting bolt to
adapter. (14) Remove the end of the park brake cable from
the actuator lever on the adapter (Fig. 121).
(15) Remove the end of the park brake cable from
the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in (Fig. 122) to com-
press the locking tabs on the park brake cable
retainer.
Fig. 119 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
Fig. 120 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 121 Park Brake Cable Attachment To Actuator
1 - ADAPTER
2 - PARK BRAKE CABLE
3 - ACTUATOR
4 - AXLE
5 - DRIVESHAFT
6 - PARK BRAKE CABLE RETAINER
7 - HORSESHOE CLIP
Fig. 122 Park Brake Cable Removal From Adapter
1 - DRIVESHAFT
2 - 1/2º WRENCH
3 - PARK BRAKE CABLE
4 - PARK BRAKE CABLE RETAINER
5 - ADAPTER
RS BRAKES5s-71
SHOES - PARKING 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)

CAUTION: Corrosion may occur between the hub/
bearing and the axle flange. If this occurs, the hub/
bearing will be difficult to remove from the axle and
disc brake caliper adapter. If the hub/bearing will
not come out by pulling on it by hand, don't not
pound on it with a hammer. Pounding on the hub/
bearing will damage it. To remove a hub/bearing
that is corroded in place, lightly tap the disc brake
caliper adapter using a soft-face hammer. This will
remove both the caliper adapter and hub/bearing
together from the axle. With a helper supporting the
caliper adapter in his hands, position Remover,
Special Tool 8214-1, on the cast housing of hub/
bearing (Fig. 127). Do not position the special tool
on the inner race of hub/bearing. Lightly strike the
Remover with a hammer to remove the hub/bearing
from the caliper adapter.(20) Remove the adapter from the rear axle.
(21) Mount the adapter in a vise using the anchor
boss for the park brake cable (Fig. 128). (22) Remove the lower return spring (Fig. 129)
from the leading and trailing park brake shoes.
Fig. 127 Hub/Bearing Removal From Caliper Adapter
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
Fig. 128 Adapter Mounted In Vise
1 - ADAPTER
2 - PARK BRAKE CABLE BOSS
3 - VISE
4 - PARK BRAKE BRAKE SHOES
Fig. 129 Lower Return Spring
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - RETURN SPRING
4 - TRAILING PARK BRAKE SHOE
RS BRAKES5s-73
SHOES - PARKING BRAKE (Continued)

(23) Remove the hold down spring and pin (Fig.
130) from the leading park brake shoe.
(24) Remove the adjuster (Fig. 131) from the lead-
ing and trailing park brake shoe. (25) Remove the leading park brake shoe (Fig.
132) from the adapter. Leading brake shoe is
removed by rotating the bottom of the brake shoe
inward (Fig. 132) until the top of the brake shoe can
be removed from the brake shoe anchor. Then remove
the upper return springs (Fig. 132) from the leading
brake shoe.
(26) Remove the upper return springs (Fig. 133)
from the trailing park brake shoe.
Fig. 130 Leading Brake Shoe Hold Down Pin And Spring
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - ALLEN WRENCH
4 - HOLD DOWN SPRING/PIN
Fig. 131 Brake Shoe Adjuster
1 - LEADING PARK BRAKE SHOE
2 - ADJUSTER
3 - TRAILING PARK BRAKE SHOE
Fig. 132 Primary Brake Shoe Remove/Install
1 - PARK BRAKE ACTUATOR
2 - ANCHOR
3 - LEADING PARK BRAKE SHOE
4 - UPPER RETURN SPRINGS
5 - TRAILING PARK BRAKE SHOE
Fig. 133 Upper Return Springs
1 - TRAILING PARK BRAKE SHOE
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - UPPER RETURN SPRINGS
5s - 74 BRAKESRS
SHOES - PARKING BRAKE (Continued)