steering rack CHRYSLER VOYAGER 2005 User Guide

(4) Using an appropriate grinder and grinding
wheel, slot the bottom hole in both sides of the strut
clevis bracket (Fig. 8).
CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.
NOTE: The strut clevis-to-knuckle bolts are installed
differently on each side of the vehicle. Left-hand-
side bolts are installed from vehicle rear to front
(Fig. 9). Right-hand-side bolts are installed from
vehicle front to rear.
(5) Position the knuckle back into the strut clevis
bracket. Using the direction indicated in the above
note, install a flanged bolt from the service package
into the upper mounting hole. Using the direction
indicated in the above note, install a cam bolt into
the bottom mounting hole (Fig. 9).
(6) Install a dog bone washer on the steering
knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service pack-
age (Fig. 10). Tighten the bolts just enough to hold
the steering knuckle in position when adjusting cam-
ber, while still allowing the steering knuckle to move
in clevis bracket.
(7) Repeat the procedure to the other side strut
clevis bracket.
(8) Reinstall both front tire and wheel assemblies
and tighten to specifications.(9) Lower the vehicle. Jounce the front and rear of
vehicle an equal amount of times.
(10) Adjust the front camber to the preferred set-
ting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket (Fig.
11). When camber is set, tighten the upper strut cle-
vis bracket bolt and lower cam bolt. Again jounce
front and rear of vehicle an equal amount of times
and verify front camber setting. Torque both front
strut to steering knuckle attaching bolts to 81 N´m
(60 ft. lbs.) plus an additional 1/4 (90É) turn after the
required torque is met.
Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area
1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE
2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON
CLEVIS BRACKET
3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
4 - STRUT CLEVIS BRACKET
Fig. 9 Package Bolts Correctly Installed
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 10 Dog Bone Washer And Nuts Installed
1 - STEERING KNUCKLE
2 - DOG BONE WASHER
3 - STRUT CLEVIS BRACKET
4 - ATTACHING NUTS
2 - 54 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

(11) If toe readings obtained are not within the
required specification range, adjust toe to meet the
preferred specification setting. Toe is adjustable
using the following procedure.
TOE
(1) Center the steering wheel and lock in place
using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(2) Loosen front inner to outer tie rod end jam
nuts (Fig. 12). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - SPECIFI-
CATIONS)
(3) Tighten tie rod jam nuts (Fig. 12) to 75 N´m
(55 ft. lbs.) torque.
(4) Adjust steering gear to tie rod boots at the
inner tie rod.
(5) Remove steering wheel clamp.
(6) Remove the alignment equipment.
(7) Road test the vehicle to verify the steering
wheel is straight and the vehicle does not wander or
pull.
STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.
(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Compare the measurements to the specifica-
tions listed in the following Curb Height Specifica-
tions charts.
Fig. 11 Camber Adjustment Cam Bolt
1 - STEERING KNUCKLE
2 - CLEVIS BRACKET CAM STOP AREAS
3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT
Fig. 12 Front Wheel Toe Adjustment
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
RSWHEEL ALIGNMENT2-55
WHEEL ALIGNMENT (Continued)

(4) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe half shaft
nut.
(5) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).
(6) Remove the disc brake caliper assembly from
the steering knuckle. Caliper assembly is removed by
first rotating top of caliper assembly away from
steering knuckle and then removing bottom of assem-
bly out from under machined abutment on steering
knuckle.(7) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 5).Do not allow the brake caliper assembly
to hang by the brake flex hose.
(8) Remove the brake rotor from the hub and bear-
ing assembly.
(9) Remove the steering knuckle-to-strut attach-
ment bolts (Fig. 6) from the steering knuckle.
(10) Pull the steering knuckle from the strut clevis
bracket.
Fig. 3 Wave Washer
1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - STUB AXLE
Fig. 4 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 5 Properly Supported Disc Brake Caliper -
Typical
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
Fig. 6 Strut To Steering Knuckle Attaching Bolts
1 - STRUT CLEVIS BRACKET
2 - NUTS AND BOLTS
3 - STEERING KNUCKLE
RSHALF SHAFT - FRONT3-3
HALF SHAFT - FRONT (Continued)

(6) Slide half shaft back into front hub and bear-
ing assembly.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckle.
CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slot-
ted) hole on the strut clevis bracket (Fig. 10).
(7) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut damper to
steering knuckle attaching bolts. Tighten both bolts
to a torque of 88 N´m (65 ft. lbs.) plus an additional
1/4 turn.
(8) Install braking disc on hub and bearing assem-
bly.
(9) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper assembly under abutment on steering
knuckle, and then rotating top of caliper against top
abutment.
(10) Install disc brake caliper adapter to steering
knuckle attaching bolts (Fig. 4). Tighten the discbrake caliper adapter attaching bolts to a torque of
169 N´m (125 ft. lbs.).
(11) Clean all foreign matter from the threads of
the outer CV joint. Install the washer and half shaft
to hub/bearing assembly nut on half shaft and
securely tighten nut.
(12) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N´m (100
ft. lbs.).
(13) Lower vehicle.
(14) With the vehicle's brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N´m (180 ft. lbs.) (Fig. 11).
(15) Install the spring wave washer on the end of
the half shaft.
(16) Install the hub nut lock, and anewcotter pin
(Fig. 2). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 2).
(17) Check for correct fluid level in transaxle
assembly. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 10 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 11 Torquing Front Half Shaft To Hub Nut
1 - TORQUE WRENCH
RSHALF SHAFT - FRONT3-5
HALF SHAFT - FRONT (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).
(22) Remove two nuts securing brake lamp switch
bracket to pedal assembly. Remove bracket.
(23) Disconnect wiring connector connecting vehi-
cle wiring harness connector to pedal wiring harness
(Fig. 58).
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
Fig. 57 Intermediate Shaft Dash Seal
And Silencer Shell
1 - INTERMEDIATE SHAFT
2 - DASH SEAL
3 - SILENCER SHELL
Fig. 58 Wiring Harness Connection
1 - VEHICLE WIRING HARNESS
2 - WIRING CONNECTOR
3 - ROUTING LOOP
RSBRAKES - BASE5-41
PEDALS - ADJUSTABLE (Continued)

(24) Unfasten routing clips retaining vehicle wir-
ing harness to pedal wiring harness (Fig. 58).
(25) Remove power brake booster input rod from
brake pedal pin by performing following:
(a) Position small screwdriver between center
tang on retaining clip and brake pedal pin (Fig.
59).
(b) Rotate screwdriver, moving retaining clip
center tang enough to allow it to pass over end of
brake pedal pin, then slide retaining clip off brake
pedal pin.
(c) Discard retaining clip.Retaining clip must
not be reused. Install NEW retaining clip
when assembling.
(d) Slide booster input rod off pedal pin.
(26) Disconnect pedal adjuster cable at brake
pedal adjustment gear box (Fig. 60).
(27) Remove pedal adjuster cable from routing loop
on steering column bracket (Fig. 60), then pull gear
box end of cable upward, out of steering column
bracket, and down right side of pedals assembly.
(28) Remove four nuts attaching power brake
booster and pedals assembly to dash panel (Fig. 61).
(29) Remove two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash.
(30) Disconnect throttle cable retainer at accelera-
tor pedal, then remove cable from pedal.
(31) Remove adjustable pedals assembly.
Fig. 59 Input Rod Brake Pedal Retaining Clip
Removal
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
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
5 - 42 BRAKES - BASERS
PEDALS - ADJUSTABLE (Continued)

INSTALLATION
(1) Install adjustable pedals assembly under
instrument panel.
(2) Attach throttle cable to accelerator pedal using
cable retainer.
(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 to 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.
(24) Install knee blocker reinforcement plate (Fig.
53).
(25) Connect parking brake release link to release
handle.
(26) Install data link diagnostic connector to
mounting hole in reinforcement plate.
(27) Install lower steering column cover/knee
blocker (Fig. 53).
(28) Install throttle cable onto throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery following special Diagnosis And Testing pro-
cedure. (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING)
(30) Test operation of adjustable pedals and all
functions that are steering column operated. If appli-
cable, reset radio and clock.
(31) Road test the vehicle to ensure proper opera-
tion of steering and brake systems.
RSBRAKES - BASE5-43
PEDALS - ADJUSTABLE (Continued)

(17) Inside vehicle, remove silencer panel under
instrument panel below steering column.
(18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 68).
(19) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 69).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 70).
CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.
REMOVAL - RHD
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4 or 5 strokes).
(2) Remove negative battery cable terminal from
battery.
(3) Remove positive battery cable terminal from
battery.
(4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
(6) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray.
(7) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(8) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
the speed control servo.
(b) Remove the two servo mounting nuts.
Fig. 68 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
Fig. 69 Booster Mounting
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 70 Booster Removal/Installation
5 - 48 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)

INSTALLATION - LEFT REAR
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park
brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 115).
(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.
INSTALLATION - FOLD-IN-FLOOR SEATING
(1) Pass the leading end of the rear parking brake
cable through the hole in the end of the intermediate
bracket (Fig. 123). Press the cable housing retainer
through the hole until the fingers on the retainer
lock it into place.
(2) Route the cable back toward the brake assem-
bly placing it in the routing clip fastened to the
underbody of the vehicle (Fig. 119). Make sure to
stay to the inside of the left stabilizer bar link while
routing either cable.
(3) If the right rear cable is being serviced, install
screws, attaching the cable routing clamps to the
rear axle (Fig. 120).
(4) Pass the cable through the hole in the brake
adapter and hook the cable eyelet to the shoe lever
(Fig. 121).
(5) Install the screw fastening the cable to the rear
brake adapter (Fig. 121).
(6) Pull straight back on the front cable button
(and pliers) and properly attach the equalizer to all
three parking brake cables (Fig. 118).
(7) Remove the locking pliers from the front park-
ing brake cable and allow the automatic self-adjust-
ing mechanism in the lever to take up any slack.
(8) Lower the vehicle.
(9) Apply and release park brake pedal 1 time.
This will seat the parking brake cables.
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE).
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the steering column cover from the
lower instrument panel.
(6) Remove the reinforcement from the lower
instrument panel.
(7) Remove the three bolts mounting the wiring
junction 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.
(8) Remove the lower bolt mounting the parking
brake lever (pedal) to the body (Fig. 124).
(9) Remove the forward nut mounting the parking
brake lever to the body (Fig. 124).
(10) Remove the upper bolt mounting the parking
brake lever to the body (Fig. 124).
(11) Pull downward on front parking brake cable
while rotating lever assembly out from behind junc-
tion block.
(12) Remove the release link from the parking
brake lever assembly.
(13) Disconnect the wiring connector from the indi-
cator lamp ground switch (Fig. 124) (Fig. 125).
Fig. 124 Parking Brake Lever Mounting
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RSBRAKES - BASE5-75
CABLE - PARKING BRAKE REAR (Continued)

(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 YOUR-
SELF AND THE PAINTED SURFACES OF THE VEHI-
CLE. 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 BRAKE FASTENER TORQUE. (Refer to 5
- BRAKES - BASE - SPECIFICATIONS)
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 & MAIN-
TENANCE/HOISTING - STANDARD PROCEDURE)
(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
punch and tap edge of sensor ear, rocking the sensor
side-to-side until free.
Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - DRIVESHAFT
4 - TONE WHEEL
5 - STEERING KNUCKLE
RSBRAKES - ABS5-91
BRAKES - ABS (Continued)