brakes fluid CHRYSLER VOYAGER 2005 Owner's Guide

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 Mopart
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)
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
5 - 40 BRAKES - BASERS
MASTER CYLINDER (Continued)

(7) Connect the brake pedal link to the torque
shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - 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.
(10) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(11) Road test vehicle to ensure proper operation of
the brakes.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster mounts on the engine
compartment side of the dash panel. It is connected
to the brake pedal by the input (push) rod (Fig. 64).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
All Left-Hand-Drive (LHD) vehicles use a 270 mm
single diaphragm vacuum power brake booster. All
Right-Hand-Drive (RHD) vehicles use a 225/200 mm
tandem diaphragm vacuum power brake booster.
Vehicles equipped with Disc/Disc brakes use a dif-
ferent power brake booster than vehicles equipped
with Disc/Drum brakes. Differences between the two
are internal. Service is the same for all boosters.
The power brake booster can be identified by the
tag attached to the body of the booster (Fig. 65). This
tag contains the production part number, the date it
was built, and who the manufacturer of the power
brake booster is.
NOTE: The power brake booster assembly is not a
repairable component and must be replaced as a
complete assembly if found to be faulty in any way.
The check valve located on the power brake
booster face is not repairable, but it can be
replaced separately from the power brake booster.The different engine combinations used in this
vehicle require different vacuum hose routings to the
power brake booster. All vacuum hoses must be
routed from the engine to the power brake booster
without kinks or excessively tight bends.
Fig. 64 Power Brake Booster (Typical)
1 - VACUUM CHECK VALVE
2 - POWER BRAKE BOOSTER ASSEMBLY
3 - INPUT ROD
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - OUTPUT ROD
Fig. 65 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
RSBRAKES - BASE5-45
PEDAL TORQUE SHAFT - RHD (Continued)

(6) Remove screw securing engine coolant filler
tube to battery tray.
(7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray.
(8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(9) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
the speed control servo.
(b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 66).
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(12) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 67). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to
power brake booster (Fig. 67).
(15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
Fig. 66 Master Cylinder And Booster
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 67 Master Cylinder Mounting
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
RSBRAKES - BASE5-47
POWER BRAKE BOOSTER (Continued)

(c) Lay speed control servo off to the side, out of
the way.
(9) If the vehicle is equipped with the 2.5L diesel
engine, remove the coolant recovery pressure con-
tainer and bracket. (Refer to 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
REMOVAL)
(10) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 71).
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(11) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the booster.
(12) Remove two nuts attaching master cylinder to
power brake booster (Fig. 72).
(13) Slide master cylinder straight out of power
brake booster. Lay master cylinder with primary and
secondary tubes to the side, out of the way.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever themaster cylinder is removed from the power brake
vacuum booster.
(14) Disconnect vacuum hose from check valve
located on booster.DO NOT REMOVE CHECK
VALVE FROM POWER BRAKE BOOSTER.
(15) Under the instrument panel, remove booster
input rod trim cover.
(16) Locate the booster input rod to brake pedal
torque shaft connection under the instrument panel.
Position a small screwdriver between the center tang
on the retaining clip (Fig. 73).
Fig. 71 RHD Master Cylinder And Power Brake
Booster
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
Fig. 72 RHD Master Cylinder Mounting
1 - PRIMARY BRAKE TUBE NUT
2 - SECONDARY BRAKE TUBE NUT
3 - MASTER CYLINDER MOUNTING NUTS
Fig. 73 Booster Input Rod Pin Retaining Clip
(Typical)
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
RSBRAKES - BASE5-49
POWER BRAKE BOOSTER (Continued)

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.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(6) Install the silencer panel below the steering
column.
(7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 77).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.(11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 67). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
(12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 66).
(13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 67).
Tighten the tube nuts to 17 N´m (145 in lbs.).
(14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.).
(16) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.).
(17) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray.
(18) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing. Securely tighten hose clamp at air cleaner hous-
ing and throttle body.
(19) Secure the engine coolant filler neck to the
battery tray with its mounting screw.
(20) Install the battery, clamp and mounting nut.
(21) Install the positive battery cable on the bat-
tery.
(22) Install the negative battery cable on the bat-
tery.
(23) Install the battery thermal guard shield.
(24) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(25) Road test vehicle to ensure operation of the
brakes.
INSTALLATION - RHD
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 75).
(2) Below instrument panel, first install the two
upper nuts mounting the booster to the dash panel,
drawing it into place, then install the two lower
mounting nuts. Tighten the mounting nuts to a
torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod.
CAUTION: When installing the brake pedal torque
shaft pin on the power brake booster input rod, do
not re-use the old retaining clip.
Fig. 77 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
RSBRAKES - BASE5-51
POWER BRAKE BOOSTER (Continued)

(4) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 78).
(5) Install booster input rod trim cover.
(6) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder, do not use a sharp tool.
(7) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(8) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 79).
(9) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(10) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 72). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
(11) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 71).
(12) If the vehicle is equipped with the 2.5L diesel
engine, install the coolant recovery pressure con-
tainer and bracket. (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY PRESS CONTAINER -
INSTALLATION)
(13) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.).
(14) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.).
(15) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray.
(16) Install the battery, clamp and mounting nut.
(17) Install the positive battery cable on the bat-
tery.
(18) Install the negative battery cable on the bat-
tery.
(19) Install the battery thermal guard shield.
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.
(20) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(21) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(22) Road test vehicle to ensure proper operation
of the brakes.
Fig. 78 Retaining Pin Installed On Brake Pedal Pin
(Typical)
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
Fig. 79 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
5 - 52 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)

PROPORTIONING VALVE SPECIFICATIONS
WHEEL
BASEDRIVE
TRAINSALES
CODEBRAKE
SYSTEMSPLIT
POINTSLOPEINLET
PRESSURE
PSIOUTLET
PRESSURE
PSI
SWB FWD BRB-BGF159DISC/
DRUM W/O
ANTILOCKVAR. 0.59 1000 PSI 675-875 PSI
REMOVAL - PROPORTIONING VALVE (HEIGHT
SENSING)
(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 proportioning valve.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the four brake tubes from the inlet and
outlet ports of the proportioning valve (Fig. 81).
(4) Remove the two bolts attaching the proportion-
ing valve and bracket to the vehicle (Fig. 81).
(5) Slide the bracket out from under rear track bar
bracket. Lower the valve down enough to pull itsactuator rod out of the axle bracket and remove the
proportioning valve from the vehicle.INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)
(1) Install the end of the actuator rod through the
axle bracket grommet and slide the proportioning
valve bracket under the rear track bar body bracket
(Fig. 81).
(2) Install the proportioning valve attaching bolts
(Fig. 81). Tighten the attaching bolts to a torque of
54 N´m (40 ft. lbs.).
(3) Install the four chassis brake lines into the
inlet and outlet ports of the proportioning valve (Fig.
81). Tighten all tube nuts to a torque of 17 N´m (145
in. lbs.).
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it.
(4) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - BASE - STANDARD
PROCEDURE).
(5) Lower the vehicle to the ground.
(6) Road test the vehicle to verify proper operation
of the brake system.
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock-back. This increases
guide pin sleeve wear due to the tendency of the cal-
iper to follow the rotor wobble.
When diagnosing a brake noise or pulsation, the
machined disc braking surface should be checked and
inspected.
Fig. 81 PROPORTIONING VALVE MOUNTING
1 - LEFT REAR OUTLET TUBE
2 - RIGHT REAR OUTLET TUBE
3 - RIGHT REAR INLET TUBE
4 - MOUNTING BOLTS
5 - LEFT REAR INLET TUBE
RSBRAKES - BASE5-55
PROPORTIONING VALVE (Continued)

SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
(9) Disconnect the park brake cable from the park
brake actuation lever.
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 92) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate.
(11) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL)(12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 93).
(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer to 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION)
(4) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(5) Install the park brake cable on the park brake
actuation lever.
(6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(8) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(9) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(10) Install brake drum.
(11) Install the wheel and tire assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification, then repeat the
Fig. 92 Removing Park Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE
2 - CABLE RETAINER
3 - 14 mm BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 93 Brake Support Plate Mounted On Bearing
Attaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
RSBRAKES - BASE5-61

tightening sequence to the full specified torque of 135
N´m (100 ft. lbs.).
(12) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(13) Remove brake pedal depressor tool.
(14) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(15) Lower the vehicle.
WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.(4) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.).
(7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 94). It is a automatic-adjust-
ing type lever.
Vehicles without Fold-in-floor seating have four
flexible steel parking brake cables. They are:
²Front
²Intermediate
²Left rear
²Right rear
Fig. 94 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5 - 62 BRAKES - BASERS
SUPPORT PLATE - DRUM BRAKE (Continued)

DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
tioning valve. The EVBP system uses the ABS system
to control the slip of the rear wheels in partial brak-
ing range. The braking force of the rear wheels is con-
trolled electronically by using the inlet and outlet
valves located in the integrated control unit (ICU).
EVBP activation is invisible to the customer since
there is no pump motor noise or brake pedal feedback.
DESCRIPTION - TRACTION CONTROL SYSTEM
Traction control reduces wheel slip and maintains
traction at the driving wheels at speeds below 56
km/h (35 mph) when road surfaces are slippery. The
traction control system reduces wheel slip by braking
the wheel that is losing traction.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves are
included on vehicles with traction control. These
valves are located inside the HCU and cannot be ser-
viced separately from the HCU.
TRACTION CONTROL LAMP
The traction control function lamp is located in the
transmission range indicator display of the instru-
ment cluster, displaying TRAC, TRAC OFF or nei-
ther depending on system mode.
The TRAC OFF lamp is controlled by a Traction
Control Off switch that is a momentary contact type
switch. The Traction Control Off switch is located on
the steering column upper shroud.
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM
There are a few performance characteristics of the
Mark 20e Antilock Brake System that may at first
seem abnormal, but in fact are normal. These char-
acteristics are described below.
NORMAL BRAKING
Under normal braking conditions, the ABS func-
tions the same as a standard base brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS BRAKING
ABS operation is available at all vehicle speeds above
3±5 mph. If a wheel locking tendency is detected during
a brake application, the brake system enters the ABS
mode. During ABS braking, hydraulic pressure in thefour wheel circuits is modulated to prevent any wheel
from locking. Each wheel circuit is designed with a set of
electric solenoids to allow modulation, although for vehi-
cle stability, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at the
very end of an ABS stop and is considered normal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into three control channels.
During antilock operation of the vehicle's brake sys-
tem, the front wheels are controlled independently
and are on two separate control channels, and the
rear wheels of the vehicle are controlled together.
The system can build and release pressure at each
wheel, depending on signals generated by the wheel
speed sensors (WSS) at each wheel and received at
the controller antilock brake (CAB).
NOISE AND BRAKE PEDAL FEEL
During ABS braking, some brake pedal movement
may be felt. In addition, ABS braking will create
ticking, popping, or groaning noises heard by the
driver. This is normal and is due to pressurized fluid
being transferred between the master cylinder and
the brakes. If ABS operation occurs during hard
braking, some pulsation may be felt in the vehicle
body due to fore and aft movement of the suspension
as brake pressures are modulated.
At the end of an ABS stop, ABS is turned off when
the vehicle is slowed to a speed of 3±4 mph. There may
be a slight brake pedal drop anytime that the ABS is
deactivated, such as at the end of the stop when the
vehicle speed is less than 3 mph or during an ABS stop
where ABS is no longer required. These conditions exist
when a vehicle is being stopped on a road surface with
patches of ice, loose gravel, or sand on it. Also, stopping
a vehicle on a bumpy road surface activates ABS
because of the wheel hop caused by the bumps.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
lockup, some wheel slip is desired in order to achieve
optimum braking performance. Wheel slip is defined
as follows: 0 percent slip means the wheel is rolling
freely and 100 percent slip means the wheel is fully
locked. During brake pressure modulation, wheel slip
is allowed to reach up to 25±30 percent. This means
that the wheel rolling velocity is 25±30 percent less
than that of a free rolling wheel at a given vehicle
speed. This slip may result in some tire chirping,
depending on the road surface. This sound should not
be interpreted as total wheel lockup.
Complete wheel lockup normally leaves black tire
marks on dry pavement. The ABS will not leave dark
black tire marks since the wheel never reaches a
fully locked condition. However, tire marks may be
noticeable as light patched marks.
5 - 88 BRAKES - ABSRS
BRAKES - ABS (Continued)