Chrysler RG Voyager. Manual - part 656

(12) Remove vacuum seal located on the mounting

flange of the master cylinder. The vacuum seal is
removed from master cylinder by carefully pulling it
off the rear of master cylinder. Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.

REMOVAL - RHD

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 or 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. 46).

(8) Disconnect primary and secondary brake tubes

from master cylinder housing (Fig. 50). 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. 50).

(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.

(12) Remove vacuum seal located on the mounting

DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)

(1) Clean master cylinder housing and brake fluid

reservoir. Use only a solvent such as Mopar Brake
Parts Cleaner or an equivalent.

(2) Remove brake fluid reservoir cap. Using a

syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.

CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.

(3) Remove the master cylinder assembly from the

power brake vacuum booster. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER

CYL-

INDER - REMOVAL).

(4) Mount the master cylinder in a vise using the

master cylinder mounting flange.

(5) Using correct size pin punch, remove the two

retaining pins between the fluid reservoir and master
cylinder housing (Fig. 51).

(6) Rock the brake fluid reservoir from side to side

while pulling up to remove it from the seal grommets
in master cylinder housing.

(7) Remove the two master cylinder housing to

brake fluid reservoir seal grommets (Fig. 52).

Fig. 50 RHD MASTER CYLINDER MOUNTING

1 - PRIMARY BRAKE TUBE NUT
2 - SECONDARY BRAKE TUBE NUT
3 - MASTER CYLINDER MOUNTING NUTS

BRAKES - BASE

5 - 37

MASTER CYLINDER (Continued)

ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)

(1) Install new master cylinder housing to brake

fluid reservoir sealing grommets in master cylinder
housing (Fig. 52).

(2) Lubricate reservoir mounting area with fresh

clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir.

(3) Be sure fluid reservoir is positioned properly on

master cylinder. Bottom of fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.

(4) Install the two fluid reservoir to master cylin-

der retaining pins (Fig. 51).

(5) Install the master cylinder assembly on the

power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER

CYLINDER

INSTALLATION)

(6) Fill fluid reservoir to its proper level as indi-

cated on the side of the fluid reservoir.

INSTALLATION

INSTALLATION - LHD

CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.

CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.

(1) Install a NEW vacuum seal on master cylinder

making sure seal fits squarely in groove of master
cylinder casting.

(2) Position master cylinder on studs of power

brake booster, aligning booster push rod with master
cylinder piston.

(3) Install the two master cylinder mounting nuts

(Fig. 49). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).

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.
48). 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.
48).

(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 Mopar

Brake Fluid or equivalent.

Fig. 51 Fluid Reservoir Retaining Pins (Typical)

1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER

Fig. 52 Master Cylinder To Fluid Reservoir Seal

Grommets

1 - SEAL GROMMETS
2 - MASTER CYLINDER

5 - 38

BRAKES - BASE

MASTER CYLINDER (Continued)

(11) Road test vehicle to ensure proper operation of

brakes.

INSTALLATION - RHD

CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.

(1) Install a NEW vacuum seal on master cylinder

making sure seal fits squarely in groove of master
cylinder casting.

(2) Position master cylinder on studs of power

brake booster, aligning booster push rod with master
cylinder piston.

(3) Install the two master cylinder mounting nuts

(Fig. 50). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).

(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 Mopar

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

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).

Fig. 53 Lower Steering Column Cover And

Reinforcement

1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER

BRAKES - BASE

5 - 39

MASTER CYLINDER (Continued)

(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

STEERING/COLUMN/

LOWER SHROUD - REMOVAL)

(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).

Fig. 54 Instrument Panel Lower Left Reinforcement

1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT

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

5 - 40

BRAKES - BASE

PEDALS - ADJUSTABLE (Continued)

Content .. 654 655 656 657 ..