torque CHRYSLER VOYAGER 2005 Repair Manual

(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)

If the hub runout does not exceed this specifica-
tion, install the rotor back on the hub, aligning the
chalk marks on the rotor with a wheel mounting
stud, two studs apart from the original stud (Fig. 87).
Tighten nuts in the proper sequence and torque to
specifications.
Recheck brake rotor runout to see if the runout is
now within specifications. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTOR - SPECIFICA-
TIONS)
If runout is not within specifications, reface or
replace the brake rotor. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE)
STANDARD PROCEDURE - BRAKE ROTOR
MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted on-car brake lathe (Fig. 88), or
replaced.
The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle's hub and bearing.NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 89) (Fig. 90). Minimum thickness
specifications can also be found in the specification
table in this section. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS)
Fig. 87 Index Rotor And Wheel Stud
1 - CHALK MARK
Fig. 88 On-Car Brake Lathe
1 - ON-CAR BRAKE LATHE
Fig. 89 Front Brake Rotor
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
Fig. 90 Rear Brake Rotor Minimum Thickness
Markings
1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM
DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE
2 - REAR ROTOR
5 - 58 BRAKES - BASERS
ROTOR (Continued)

Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required. Specifi-
cations for brake rotor machining can be found in
this section's specification table. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
SPECIFICATIONS)
REMOVAL - FRONT BRAKE ROTOR
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly.
(3) Remove the two mounting bolts securing the
disc brake caliper adapter with brake caliper to the
steering knuckle (Fig. 91).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 91).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove any retainer clips from the wheel
mounting studs.
(6) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 91).
INSTALLATION - FRONT BRAKE ROTOR
(1) Install the brake rotor back on the hub and
bearing (Fig. 91).(2) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 91).
(3) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
Fig. 91 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RSBRAKES - BASE5-59
ROTOR (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)

(27) Remove the hold down spring and pin (Fig.
148) from the trailing park brake shoe.
(28) Remove the trailing park brake shoe from the
adapter.
(29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(3) Install the hold down spring and pin (Fig. 148)
on the trailing park brake shoe.
(4) Install the upper return springs (Fig. 147) on
the trailing park brake shoe.
(5) Install the upper return springs on the leading
park brake shoe (Fig. 146). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter.
(6) Install the adjuster (Fig. 145) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.(7) Install the hold down spring and pin (Fig. 144)
on the leading park brake shoe.
(8) Install the lower return spring (Fig. 143) on
the leading and trailing park brake shoes.When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 143).
(9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle.
(10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 149).
(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 140).
(12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.).
(13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 137). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs).
(14) FWD only - Install the wheel speed sensor in
the following fashion:
(a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
Fig. 148 Trailing Brake Shoe Hold Down Pin And
Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
Fig. 149 Adapter Installed On Mounting Bolts (AWD
Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
5 - 84 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

until it snaps into place on the metal retaining
clip.
(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.
(15) Install the park brake cable into its mounting
hole in the adapter.Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter.
(16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 135).
(17) Attach park brake cable to adapter using
mounting bolt.
(18) Remove the locking pliers (Fig. 131) from the
front park brake cable.
(19) Adjust the park brake drum-in-hat brake
shoes. (Refer to 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS).
(20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 133).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 132).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.).
(23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 130) on the stub shaft of
the outer C/V joint.
(24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.).
(26) AWD only - Install the spring washer (Fig.
129) on the stub shaft of the outer C/V joint.
(27) AWD only - Install the nut retainer and cotter
pin (Fig. 128) on the stub shaft of the outer C/V joint.
(28) 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.).
(29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 150). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
Fig. 150 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
RSBRAKES - BASE5-85
SHOES - PARKING BRAKE (Continued)

(5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent,accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
151).
(6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 152).
(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 153).
(8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes.(9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Fig. 150). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 135 N´m (100 ft. lbs.).
(16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
Fig. 151 Measuring Park Brake Drum Diameter
Fig. 152 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 153 Setting Gauge To Park Brake Shoe
Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
5 - 86 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................87
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................87
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............88
DESCRIPTION - TRACTION CONTROL
SYSTEM............................88
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 88
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............89
OPERATION - TRACTION CONTROL
SYSTEM............................89
CAUTION.............................90
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................90
SPECIFICATIONS
ABS FASTENER TORQUE...............91
TONE WHEEL RUNOUT................91
WHEEL SPEED SENSOR AIR GAP........91
FRONT WHEEL SPEED SENSOR
REMOVAL.............................91
INSTALLATION.........................92
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................92INSTALLATION.........................92
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................93
INSTALLATION.........................93
TONE WHEEL
INSPECTION - TONE WHEEL..............94
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................94
REMOVAL.............................95
INSTALLATION.........................95
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................95
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION........................100
OPERATION..........................101
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION........................102
OPERATION..........................102
REMOVAL
REMOVAL - LHD.....................102
REMOVAL - RHD.....................104
DISASSEMBLY - ICU...................105
ASSEMBLY - ICU......................106
INSTALLATION
INSTALLATION - LHD.................106
INSTALLATION - RHD.................107
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE SYSTEM
This section covers the physical and operational
descriptions and the on-car service procedures for the
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control.
The purpose of the antilock brake system (ABS) is
to prevent wheel lockup under braking conditions on
virtually any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
DESCRIPTION - ANTILOCK BRAKE SYSTEM
(EXPORT)
Four-wheel disc antilock brakes are standard on all
models. The Mark 20e antilock brake system is used
on all models. Depending on whether the vehicle is a
left-hand drive (LHD) or right-hand drive (RHD)
model, the integrated control unit (ICU) is located in
one of two locations. On LHD models, the ICU is
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
RSBRAKES - ABS5-87