Chrysler RG Voyager. Manual - part 659

(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).

(17) Rotate screwdriver enough to allow retaining

clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal torque shaft
pin. Discard retaining clip. It is not to be
reused. Replace only with a new retaining clip
when assembling.

(18) Remove booster input rod from pedal torque

shaft pin.

(19) Remove the three easily accessed mounting

nuts attaching power brake booster to dash panel
and loosen fourth (Fig. 74). As fourth nut is loosened,
push the booster forward periodically until the nut
can be completely removed.

(20) Slide power brake booster forward and remove

through engine compartment (Fig. 75).

CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.

INSTALLATION

INSTALLATION - LHD

(1) Position power brake booster on dash panel

using the reverse procedure of its removal (Fig. 70).

It may be necessary to push in on booster input rod
as it is guided through the dash panel.

(2) Install the four nuts mounting the booster to

the dash panel (Fig. 69). Tighten the mounting nuts
to a torque of 29 N·m (250 in. lbs.).

Fig. 73 Booster Input Rod Pin Retaining Clip

(Typical)

1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN

Fig. 74 Booster, Torque Shaft And Pedal Mounting

1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT

Fig. 75 RHD Booster Removal/Installation

1 - POWER BRAKE BOOSTER
2 - MASTER CYLINDER

BRAKES - BASE

5 - 49

POWER BRAKE BOOSTER (Continued)

(3) Using lubriplate, or equivalent, coat the sur-

face of the brake pedal pin where it contacts the
booster input rod.

CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.

(4) Install booster input rod on brake pedal pin

and install a NEW retaining clip (Fig. 76).

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

not

adjusted

properly

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-

Fig. 76 Retaining Pin Installed On Brake Pedal Pin

1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD

Fig. 77 Vacuum Seal (Typical)

1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL

5 - 50

BRAKES - BASE

POWER BRAKE BOOSTER (Continued)

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.

(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: 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.).

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

BRAKES - BASE

5 - 51

POWER BRAKE BOOSTER (Continued)

(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

not

adjusted

properly

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.

PROPORTIONING VALVE

DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)

NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.

Vehicles not equipped with ABS use a height sens-

ing proportioning valve. It is mounted to the body of
the vehicle above the rear axle (Fig. 80). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.

CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.

CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are

prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.

OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)

Vehicles not equipped with ABS use a height sens-

ing proportioning valve.

The height sensing proportioning valve operates

similarly to a standard proportioning valve in the fol-
lowing way. As hydraulic pressure is applied to the
valve, full input hydraulic pressure is supplied to the
rear brakes up to a certain pressure point, called the
split point. Beyond the split point, the proportioning
valve reduces the amount of hydraulic pressure to
the rear brakes according to a given ratio. Thus, on
light

brake

applications,

approximately

equal

hydraulic pressure will be transmitted to both the
front and rear brakes. Upon heavier brake applica-
tions, the hydraulic pressure transmitted to the rear
brakes will be lower than the front brakes. This will
prevent premature rear wheel lockup and skid.

Here is how the height sensing proportioning valve

differs from a standard proportioning valve. As the
height of the rear suspension changes, the height
sensing portion of the proportioning valve changes
the split point of the proportioning valve. When the
height of the rear suspension is low, the proportion-
ing valve interprets this as extra load and the split
point of the proportioning valve is raised to a higher
pressure to allow for more rear braking. When the

Fig. 80 HEIGHT SENSING PROPORTIONING VALVE

1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE

5 - 52

BRAKES - BASE

POWER BRAKE BOOSTER (Continued)

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