Chrysler RG Voyager. Manual - part 655

CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.

JUNCTION BLOCK

DESCRIPTION - NON-ABS JUNCTION BLOCK

A junction block is used on vehicles that are not

equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
located on the driver’s side of the front suspension
cradle/crossmember below the master cylinder (Fig.
44).

It has six threaded ports to which the brake tubes

connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.

OPERATION - NON-ABS JUNCTION BLOCK

The junction block distributes the brake fluid com-

ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated
control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.

NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.

REMOVAL - NON-ABS JUNCTION BLOCK

(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 junction block.

(2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,

perform the following:

(a) Disconnect the battery positive cable.
(b) Remove the battery (Refer to 8 - ELECTRI-

CAL/BATTERY SYSTEM/BATTERY - REMOVAL).

tank built into the battery tray.

(d) Remove the screw securing the coolant filler

neck to the battery tray.

(e) Remove the battery tray (Refer to 8 - ELEC-

TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).

(f) Remove the fasteners and move the speed

control servo off to the side, out of the way.

CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system.

(4) Remove the four chassis brake tubes from the

top of the junction block (Fig. 44).

(5) Remove the primary and secondary brake

tubes from the top of the junction block.

(6) Remove the bolts attaching the junction block

mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.

INSTALLATION - NON-ABS JUNCTION BLOCK

(1) Install the junction block and mounting bracket

on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N·m (250 in. lbs.).

(2) Install the primary and secondary brake tubes

from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N·m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement

with

rubber

isolated

suspension

crossmember.

Fig. 44 NON-ABS JUNCTION BLOCK

1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS

BRAKES - BASE

5 - 33

FLUID (Continued)

(3) Install the four chassis brake tubes into the

outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N·m (145 in. lbs.).

(4) If the vehicle is equipped with speed control,

perform the following:

(a) Install the speed control servo with its

mounting nuts.

(b) Connect the wiring harness to the speed con-

trol servo.

TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).

(d) Install the screw securing the coolant filler

neck to the battery tray.

(e) Reconnect the vacuum hose connector at the

tank built into the battery tray.

(f) Install the battery (Refer to 8 - ELECTRI-

CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).

(g) Install the battery shield.

(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of

the battery.

(7) Bleed the brake system thoroughly to ensure

that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).

(8) Road test the vehicle to verify proper operation

of the brake system.

MASTER CYLINDER

DESCRIPTION

The master cylinder is located on the power brake

booster in the engine compartment on the driver’s
side (Fig. 45). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.

CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.

For information on master cylinder application,

bore and type, view the following table:

BRAKE SYSTEM

MASTER CYLINDER

BORE/TYPE

Disc/Drum - ABS

23.8 mm (15/16 in.)

Conventional

Compensating Port

Disc/Drum - Non-ABS

23.8 mm (15/16 in.)

Conventional

Compensating Port

Disc/Disc - ABS

25.4 mm (1.0 in.)

Conventional

Compensating Port

Disc/Disc ABS With
Traction Control

25.4 mm (1.0 in.) Dual

Center Port

CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.

The body of the master cylinder is an anodized alu-

minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections.

The brake fluid reservoir is mounted on the top of

the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir.

The master cylinder is not a repairable component

and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.

Fig. 45 Master Cylinder And Booster Location

1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER

5 - 34

BRAKES - BASE

JUNCTION BLOCK (Continued)

CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.

DESCRIPTION - RHD

The master cylinder used on right hand drive

(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 46). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.

OPERATION

When the brake pedal is depressed, the master cyl-

inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly.

The master cylinder primary outlet port supplies

hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.

STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING

CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.

(1) Clamp master cylinder in a vise.

NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with ABS or not. ABS
equipped master cylinders require the additional
use of ISO style flare adapters supplied in Special
Tool Package 8822 to be used in conjunction with
Bleeder Tubes, Special Tool Package 8358.

(2) Attach special tools for bleeding master cylin-

der in the following fashion:

(a) For non-ABS control equipped master

cylinders, thread a Bleeder Tube, Special Tool
8358–1, into each outlet port. Tighten each tube to
17 N·m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 47).

(b) For ABS

equipped

master

cylinders,

thread one Adapter, Special Tool 8822–2, in each
outlet port. Tighten Adapters to 17 N·m (145 in.
lbs.) torque. Next, thread a Bleeder Tube, Special
Tool 8358–1, into each Adapter. Tighten each tube
to 17 N·m (145 in. lbs.) torque. Flex bleeder tubes
and place open ends into mouth of fluid reservoir
as far down as possible (Fig. 47).

NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level.

(3) Fill brake fluid reservoir with Mopar

t brake

fluid or equivalent conforming to DOT 3 (DOT 4 and

Fig. 46 RHD MASTER CYLINDER AND POWER

BRAKE BOOSTER

1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER

Fig. 47 Master Cylinder Set Up For Bleeding

1 - BLEEDER TUBES 8358
2 - WOODEN DOWEL
3 - ADAPTER 8822-2 (USE ONLY ON ABS EQUIPPED MASTER
CYLINDERS)
4 - ADAPTER 8822-2 (USE ONLY ON ABS EQUIPPED MASTER
CYLINDERS)

BRAKES - BASE

5 - 35

MASTER CYLINDER (Continued)

DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.

(4) Using a wooden dowel as a pushrod (Fig. 47),

slowly depress master cylinder pistons, then release
pressure, allowing pistons to return to released posi-
tion. Repeat several times until all air bubbles are
expelled. Make sure fluid level stays above tips of
bleeder tubes in reservoir while bleeding.

(5) Remove bleeder tubes from master cylinder

outlet ports, then plug outlet ports and install fill cap
on reservoir.

(6) Remove master cylinder from vise.
(7) Install master cylinder on vehicle. (Refer to 5 -

BRAKES - BASE/HYDRAULIC/MECHANICAL/MAS-
TER CYLINDER - INSTALLATION)

REMOVAL

REMOVAL - LHD

CAUTION: Vacuum in the power brake booster must
be pumped down (removed) before removing mas-
ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle’s engine not
running, until a firm feeling brake pedal is achieved.

(1) With engine not running, pump brake pedal

until a firm pedal is achieved (4-5 strokes).

(2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
(5) Remove nut and clamp securing battery to tray,

remove battery.

(6) Thoroughly clean all surfaces of the brake fluid

reservoir and master cylinder. Use only solvent such
as Mopar

t Brake Parts Cleaner or equivalent.

(7) Remove wiring harness connector from brake

fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 48).

(8) Disconnect primary and secondary brake tubes

from master cylinder housing (Fig. 48). Install seal-
ing plugs in the now open brake tube outlet ports.

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.

(9) Clean area where master cylinder assembly

attaches to power brake booster. Use only a solvent
such as Mopar

t Brake Parts Cleaner or equivalent.

(10) Remove two nuts attaching master cylinder to

power brake booster (Fig. 49).

(11) Slide master cylinder straight out of power

brake booster.

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.

Fig. 48 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. 49 MASTER CYLINDER MOUNTING

1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU

5 - 36

BRAKES - BASE

MASTER CYLINDER (Continued)

Content .. 653 654 655 656 ..