Content .. 647 648 649 650 ..

Chrysler RG Voyager. Manual - part 649

(4) After 4 to 8 ounces of brake fluid has been bled

through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate a
good

bleed

the

hydraulic

system

has

been

obtained.

(5) Repeat the procedure at all the other remain-

ing bleeder screws.

(6) Check pedal travel. If pedal travel is excessive

or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.

(7) Perform a final adjustment of the rear brake

shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.

SPECIFICATIONS

BRAKE FASTENER TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

ABS ICU Mounting Bolts To
Bracket

—

ABS ICU Mounting
Bracket-To-Cradle Bolts

250

ABS CAB-To-HCU Mounting
Screws

—

ABS Wheel Speed Sensor
Head Mounting Bolt - Front

—

115

ABS Wheel Speed Sensor
Head Mounting Bolt - Rear

—

Adjustable Pedal Position
Sensor Mounting Screws

7.5

—

Adjustable Pedal Module
Mounting Screws

2.0

—

Brake Tube Nuts

—

145

Brake Hose Intermediate
Bracket Bolt

—

105

Brake Hose-To-Caliper
Mounting Bolt

—

Disc Brake Caliper Guide
Pin Bolts

—

Disc Brake Caliper Bleeder
Screw

—

125

Drum Brake Wheel Cylinder
Mounting Bolts

—

Drum Brake Wheel Cylinder
Mounting Bleeder screw

—

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Drum Brake Support Plate
Mounting Bolts

130

—

Junction Block (Non-ABS
Brakes) Mounting Bolts

250

Master Cylinder Mounting
Nuts

225

Power Brake Booster
Mounting Nuts

250

Proportioning Valve
Mounting Bolts

—

Proportioning Valve Axle
Bracket Mounting Bolt

—

175

Parking Brake Lever (Pedal)
Mounting Bolts And Nut

250

Wheel Mounting (Lug) Nuts

135

100

—

SPECIAL TOOLS

BASE BRAKE SYSTEM

Tubes, Master Cylinder Bleed 8358

Adapter, Master Cylinder Pressure Bleed Cap 6921

BRAKES - BASE

5 - 9

BRAKES - BASE (Continued)

BRAKE FLUID LEVEL SWITCH

DESCRIPTION

The brake fluid level switch is located in the brake

fluid reservoir of the master cylinder (Fig. 3).

OPERATION

The purpose of the brake fluid level switch is to

provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:

• Abnormal loss of brake fluid in the master cyl-

inder fluid reservoir resulting from a leak in the
hydraulic system.

• Brake shoe linings which have worn to a point

requiring replacement.

As the brake fluid drops below the minimum level,

the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid. If
the brake fluid level has dropped below the add
line in the master cylinder fluid reservoir, the
entire

brake

hydraulic

system

should

checked for evidence of a leak.

REMOVAL

(1) Remove wiring harness connector from brake

fluid reservoir level switch (Fig. 3).

(2) Using fingers, compress the retaining tabs on

the opposite end of brake fluid level switch.

(3) With retaining tabs compressed, grasp the con-

nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.

INSTALLATION

(1) Insert brake fluid level switch into left side of

brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.

(2) Connect vehicle wiring harness connector to

brake fluid level switch (Fig. 3).

Dial Indicator, C-3339

Gauge, Brake Shoe C-3919

Handle, Universal C–4171

Installer, Dust Boot C-4689 or C-4842

Fig. 3 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

5 - 10

BRAKES - BASE

BRAKES - BASE (Continued)

ADJUSTABLE PEDALS
SWITCH

REMOVAL

The adjustable pedals switch is located in the

steering column lower shroud. Remove the shroud,
then remove the switch. (Refer to 19 - STEERING/
COLUMN/LOWER SHROUD - REMOVAL)

INSTALLATION

The adjustable pedals switch is located in the

steering column lower shroud. Install the switch in
the shroud, then install the shroud. (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION)

Once installed, test for proper operation of the

adjustable pedals.

HYDRAULIC/MECHANICAL

DESCRIPTION

DESCRIPTION - DISC BRAKES (FRONT)

Each front disc brake consists of the following com-

ponents:

• Brake Rotor

• Brake Caliper

• Brake Caliper Adapter

• Shoes (Pads)
There are two non-interchangeable front disc brake

systems. One is manufactured by TRW and the other
by Continental Teves.

CAUTION: Components used on the TRW brakes
are not interchangeable with the Continental Teves
brakes. The two different systems must not be
mixed. Improper performance, noise and increased
stopping distance can occur.

The TRW front brake caliper is a one piece casting

containing a single 66 mm diameter piston bore (Fig.
4) with a phenolic piston. The caliper mounts to a
caliper adapter using two guide pin bolts that thread
into guide pins slid into the caliper adapter (Fig. 5).
The pins are lubricated and have boots that seal
them in place in the adapter.

The Continental Teves front brake caliper is a one

piece casting containing a single piston 66 mm diam-
eter bore (Fig. 4) with a phenolic piston. The caliper
mounts to a caliper adapter using two guide pin bolts
that thread into the caliper adapter and slide on
bushings mounted in the caliper.

CAUTION: TRW and Continental Teves calipers are
not interchangeable. Each caliper is specifically
designed for the unique brake system. If calipers
are interchanged, improper performance, noise and
increased stopping distance can occur.

The two different brake calipers use different

devices to control rattling. While the TRW brakes use
spring clips that mount at the ends of the shoes in
the adapters, Continental Teves brakes use a clip on
the rear of the inboard pad to hold it to the piston
and a larger clip on the outside of the caliper, holding
it to the adapter (Fig. 6).

Fig. 4 Front Disc Brake Calipers

1 - CONTINENTAL TEVES CALIPER (66 mm bore)
2 - TRW CALIPER (66 mm bore)
3 - GUIDE PIN BOLT
4 - GUIDE PIN AND BOOT
5 - CALIPER ADAPTER
6 - GUIDE PIN BOLT
7 - GUIDE PIN BUSHING
8 - CALIPER ADAPTER

Fig. 5 Guide Pins And Boots

1 - PINS
2 - BOOTS

BRAKES - BASE

5 - 11

All brake caliper adapters mount to the steering

knuckle in the same way using two mounting bolts.

The brake rotors are also different depending on

brake system. The TRW front brakes utilize an
inverted-hat style rotor. This rotor is externally
vented meaning the inner most diameter of the brak-
ing disc vents to the outboard side (or face) of the
rotor (Fig. 7). The Continental Teves front brakes uti-
lize the familiar internally-vented hat style rotor.
Internally-vented refers to the fact that the inner
most diameter of the braking disc vents to the
inboard side of the rotor (Fig. 7).

CAUTION: Do not mix rotor types on the same vehi-
cle. If brake rotors are mixed, noise and wear prob-
lems can result.

DESCRIPTION - DISC BRAKES (REAR)

There are several distinctive features to the rear

disc brakes on this vehicle (Fig. 8). The single piston,
floating caliper rear disc brake system includes a hub
and bearing assembly, adapter, rotor, caliper, and
brake shoes.

This vehicle is equipped with a caliper having a 42

mm (1.65 in.) piston and uses a 15 inch solid non-
vented brake rotor. The brake rotor is described as a
drum-in-hat style because of its dual role as a brak-
ing disc and parking brake drum.

The parking brake system on vehicles equipped

with rear disc brakes consists of a small duo-servo
drum brake mounted to the caliper adapter and uses
the interior of the rear disc brake rotor as a drum
(hat section of drum-in-hat style brake rotor).

The outboard rear disc brake shoes (pads) are side-

oriented. The shoes are marked indicating which side
they belong on.

DESCRIPTION - DISC BRAKES (EXPORT)

All vehicles are equipped with Four-Wheel-Disc

brakes. Both 15” (BRE) and 16” (BR3) disc/disc brake
systems are available. The disc brakes are manufac-
tured by Continental Teves. The BR3 system is stan-

Fig. 6 Anti-Rattle Devices On Calipers

1 - CONTINENTAL TEVES CALIPER
2 - TRW CALIPER
3 - ANTI-RATTLE CLIP
4 - ANTI-RATTLE CLIP

Fig. 7 Externally and Internally Vented Rotors

(Cross-Sectional View)

1 - EXTERNAL VENTS (TRW and Continental Teves BR3)
2 - INTERNAL VENTS (Continental Teves BRE)

Fig. 8 Rear Disc Brakes

1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT

5 - 12

BRAKES - BASE

HYDRAULIC/MECHANICAL (Continued)

Content .. 647 648 649 650 ..