1996 CHRYSLER VOYAGER brakes

BRAKES
CONTENTS
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION........................ 1
DESCRIPTION AND OPERATION
MASTER CYLINDER..................... 1
DIAGNOSIS AND TESTING
MASTER CYLINDER FLUID LEVEL CHECK . . . 2REAR DRUM BRAKE ADJUSTMENT........ 1
REMOVAL AND INSTALLATION
BRAKE PEDAL TORQUE SHAFT ASSEMBLY . . 4
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES........ 2
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle contains
the same components as brake systems described in
group 5 of the service manual, with the exception of
the brake pedal system and master cylinder. These
differences are mainly related to service procedures.
The major differences are as follows:
²Use of a torque shaft assembly to transfer brake
pedal travel to the power brake booster and master
cylinder on the left side of the vehicle
²A unique power brake booster and master cylin-
der.
Refer to the Base Brake System Component
Description in the General Information section of
group 5 for more information on components used in
the base brake system.
DESCRIPTION AND OPERATION
MASTER CYLINDER
The master cylinder used on this vehicle functions
the same as master cylinders used in other brake
systems. Refer to the Master Cylinder in the Descrip-
tion and Operation section of group 5 for more infor-
mation.
DIAGNOSIS AND TESTING
REAR DRUM BRAKE ADJUSTMENT
The rear drum brakes on front wheel drive vehicles
automatically adjust, when required, during the nor-
mal operation of the vehicle every time the brakes
are applied. Use the following procedure to test the
operation of the automatic adjuster.
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the adjustment slot in each brake support
plate to provide visual access of brake adjuster star
wheel. Disconnect parking brake cable from one side
of the vehicle at the equalizer under the vehicle at
the left frame rail. Working on the side of the vehicle
that parking brake cable is connected to, hold the
adjuster lever off the star wheel with a suitable tool,
and loosen the star wheel approximately 30 notches
in relation to the adjuster lever. This is to eliminate
the possibility that the brake is already properly
adjusted. Reconnect the parking brake cable and
repeat the procedure for the other side of the vehicle.
Fig. 1 Master Cylinder Assembly
NS/GSBRAKES 5 - 1

Upon application of the brake pedal, the lever
should move down, turning the star wheel. A definite
rotation of the star wheel should be seen if the auto-
matic adjuster is working properly. If no rotation of
the star wheel is observed when the pedal is consec-
utively pressed and released, the respective drum
will have to be removed and the adjuster serviced.
MASTER CYLINDER FLUID LEVEL CHECK
The master cylinder used in this vehicle has the
same fluid level markings as the master cylinders
used in other brake systems on the side of the fluid
resevoir. Refer to the Master Cylinder Fluid Level
Check in the Diagnosis and Testing section of group
5 for more information
REMOVAL AND INSTALLATION
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance group of this service manual.
(2) Remove the intermediate and left rear park
brake cable from the park brake cable equalizer (Fig.
2).
(3) Remove the front park cable housing retainer
from body outrigger bracket (Fig. 3). Cable is remov-
able by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.(4) Remove the two (2) retaining nuts and (2)
retaining bolts from the bottom of the parking brake/
gearshift lever bracket.
(5) Lower vehicle.
(6) Carefully lift the base of the gearshift boot
from the gearshift console to access the screws (Fig.
4).
Fig. 2 Park Brake Cable Attachment To Equalizer
Fig. 3 Front Park Brake Cable Attachment To Body
Fig. 4 Console and Gearshift boot
5 - 2 BRAKESNS/GS
DIAGNOSIS AND TESTING (Continued)

(7) Remove the four (4) retaining screws (Fig. 5).
(8) Pull the parking brake lever to the ªupº posi-
tion and lift the console (Fig. 5).
(9) Tilt the base of the gearshift boot and carefully
push through the opening in the console while lifting.
(10) Remove the three (3) nuts at the base of the
parking brake assembly.
(11) Release the parking brake assembly and lift
assembly off of the parking brake/gearshift lever
bracket.
(12) Unhook the loop on the end of the parking
brake from the equalizer bar on the parking brake/
gearshift lever bracket.
(13) Compress the parking brake cable retainer by
sliding a 14 mm box wrench over the cable retainer
and compress the three (3) retaining fingers.
(14) Remove the three (3) screws from the parking
brake grommet on the floor pan of the passenger
compartment.
(15) Lift the parking brake /gearshift lever bracket
and slide the parking brake cable out.
(16) Pull the cable through the floor pan from
inside the vehicle.
INSTALL
(1) Pass park brake cable assembly through hole
in floor pan from the inside of the vehicle.
(2) Pass cable strand button through the hole in
the pedal assembly bracket.
(3) Install parking brake cable to the brake/gear-
shift lever bracket by lifting the bracket and sliding
the cable in.
(4) Install the three (3) screws to the parking
brake grommet on the floor pan of the passenger
compartment.
(5) Compress the parking brake cable retainer by
sliding a 14 mm box wrench over the cable retainer
and compress the three (3) retaining fingers.
(6) Hook the loop on the end of the parking brake
to the equalizer bar on the parking brake/gearshift
lever bracket.
(7) Attach the parking brake assembly and place
assembly on the parking brake/gearshift lever
bracket.
(8) Install the three (3) nuts at the base of the
parking brake assembly.
(9) Pull the parking brake lever to the ªupº posi-
tion.
(10) Place the console over the parking brake/gear-
shift lever and tilt the base of the gearshift boot and
carefully pull it through the opening in the console.
(11) Install the four (4) retaining screws (Fig. 5).
(12) Carefully press the three (3) clips at the base
of the gearshift boot into the slots on the gearshift
console.
(13) Raise the vehicle.
(14) install the two (2) retaining nuts and (2)
retaining bolts to the bottom of the parking brake/
gearshift lever bracket.
(15) Install the front park cable housing retainer
to the body outrigger bracket (Fig. 3). Cable is
installed by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.
(16) Install the intermediate and left rear park
brake cable to the park brake cable equalizer (Fig. 2).
(17) Lower the vehicle.
Fig. 5 Console Retaining Screws
NS/GSBRAKES 5 - 3
REMOVAL AND INSTALLATION (Continued)

BRAKE PEDAL TORQUE SHAFT ASSEMBLY
REMOVE
(1) Disconnect Brake Pedal Switch Electrical Con-
nector
(2) Loosen the six (6) retaining nuts from the
Brake Pedal Bracket. Do not remove nuts from studs.
(Fig. 6)
(3) Remove steering column intermediate shaft.
Loosen 72 and 36 way electrical connector brackets.
Move components out of the way of the brake pedal
bracket.
(4) Access the brake booster bracket inside the
passenger compartment. Remove the retaining clip
from brake pedal torque shaft.Discard retaining
clip. It is not to be re-used. Replace only with a
new clip when reassembled.(Fig. 7)(5) Loosen the retaining nut (1) from the Brake
Booster Bracket in the engine compartment. Do not
remove nut from stud. Loosen the four Brake Booster
retaining nuts from inside the passenger compart-
ment. Do not remove nuts from stud (Fig. 6)
(6) The pedal arm, link and pedal bracket can be
disconnected from the torque shaft to make it easier
to remove.
(7) Remove torque shaft from vehicle
INSTALL
(1) Install torque shaft. Reconnect pedal arm, link
and pedal bracket assembly to torque shaft as neces-
sary.
(2) Tighten the retaining nut (1) for the Brake
Booster Bracket in the engine compartment. Tighten
the four (4) Brake Booster retaining nuts from inside
the passenger compartment.
(3) Install new retaining clip on torque shaft.
(4) Install steering column intermediate shaft.
Install 72 and 36 way connector brackets.
(5) Tighten the six (6) retaining nuts for the Brake
Pedal Bracket assembly.
(6) Connect the Brake Pedal Switch connector.
Fig. 6 Torque Shaft and Brake Pedal Assembly
Fig. 7 Brake Vacuum Booster Bracket
5 - 4 BRAKESNS/GS
REMOVAL AND INSTALLATION (Continued)

friction area should be slightly concave, with the
inner diameter 0.02 mm to 0.1 mm (.0008 in. to .0039
in.) below the outer diameter. It should also be free
from discoloration, burned areas, cracks, grooves, or
ridges.
Using a surface plate, test cover for flatness. All
sections around attaching bolt holes should be in con-
tact with surface plate within .015 inch.
The cover should be a snug fit on flywheel dowels.
If the clutch assembly does not meet these require-
ments, it should be replaced.
INSTALLATION
(1) Position the clutch and pressure plate onto the
flywheel.
(2) Insert the universal clutch alignment tool into
the clutch disc.
(3) To avoid distortion of the pressure plate, bolts
should be tightened a few turns at a time (Fig. 19).
Use a crisscross pattern until all bolts are seated.
Tighten pressure plate bolts to 27 N´m (20 ft. lbs.).
(4) Remove the universal clutch alignment tool.
(5) Install the transaxle, refer to Group 21, Tran-
saxle.
(6) Fill transaxle to the proper level with the spec-
ified lubricant.
(7) While the vehicle is elevated slightly, run the
transaxle through all the forward gears. Apply
brakes and shift into reverse. Run the transaxle
through reverse gear.
(8) Check the transaxle for leaks and recheck the
level of the transaxle lubricant.
CLUTCH RELEASE BEARING AND FORK
Remove the transaxle from the vehicle. See Group
21, for removal and installation procedures.
REMOVAL
(1) Remove clutch release shaft E-clip (Fig. 20).
(2) Remove the clutch release shaft and then slide
the fork and bearing assembly off the bearing pilot
(Fig. 21).
Fig. 19 2.5 Diesel Clutch Assembly
Fig. 20 E-clip at Clutch Release Lever Shaft
Fig. 21 Clutch Release Shaft
6 - 14 CLUTCHNS/GS
REMOVAL AND INSTALLATION (Continued)

VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION........................... 2
POWERTRAIN CONTROL MODULE.......... 2
SERVO CABLE.......................... 2
SPEED CONTROL SERVO.................. 1
SPEED CONTROL SWITCHES.............. 1
STOP LAMP SWITCH..................... 2
VACUUM RESERVOIR.................... 3
VEHICLE SPEED AND DISTANCE............ 3
DIAGNOSIS AND TESTING
CHECKING FOR DIAGNOSTIC CODES........ 3
ELECTRICAL TESTS AT POWERTRAIN
CONTROL MODULE..................... 6OVERSHOOT/UNDERSHOOT FOLLOWING
SPEED CONTROL SET................... 3
ROAD TEST............................ 3
SERVO VACUUM TEST.................... 6
SPEED CONTROL ELECTRICAL TEST........ 4
SPEED CONTROL SWITCH TEST............ 6
STOP LAMP SWITCH TEST................ 6
VACUUM SUPPLY TEST................... 8
VEHICLE SPEED SENSOR................. 8
REMOVAL AND INSTALLATION
POWERTRAIN CONTROL MODULE.......... 9
SPEED CONTROL CABLE.................. 9
SPEED CONTROL SERVO.................. 8
SPEED CONTROL SWITCHES.............. 9
STOP LAMP SWITCH.................... 9
VACUUM RESEROIR..................... 10
VEHICLE SPEED SENSOR................ 10
GENERAL INFORMATION
INTRODUCTION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the powertrain control module,
located next to battery. The controls are located on
the steering wheel and consist of the ON/OFF, SET,
RESUME/ACCEL, CANCEL and DECEL buttons
(Fig. 1).
DESCRIPTION AND OPERATION
SPEED CONTROL SERVO
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The PCM controls the sole-
noid valve body. The solenoid valve body controls the
application and release of vacuum to the diaphragm
of the vacuum servo. The servo unit cannot be
repaired and is serviced only as a complete assembly.
SPEED CONTROL SWITCHES
There are two separate switch pods that operate
the speed control system. The steering-wheel-
mounted switches use multiplexed circuits to provide
inputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owner's manual for more information on speed
control switch functions and setting procedures.
When speed control is selected by depressing the
ON switch, the PCM allows a set speed to be stored
in RAM for speed control. To store a set speed,
depress the SET switch while the vehicle is moving
at a speed between 30 and 85 mph. In order for the
speed control to engage, the brakes cannot be
applied, nor can the gear selector be indicating the
transmission is in Park or Neutral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal
Fig. 1 Speed Control Switches
NSVEHICLE SPEED CONTROL SYSTEM 8H - 1

²Depressing the OFF switch
²Depressing the CANCEL switch.
NOTE: Depressing the OFF switch or turning off
the ignition switch will erase the set speed stored
in the PCM.
For added safety,the speed control system is pro-
grammed to disengaged for any of the following con-
ditions:
²An indication of Park or Neutral
²An rpm increase without a VSS signal increase
(indicates that the clutch has been disengaged)
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)
²The VSS signal increases at a rate of 10 mph
per second (indicates that the co-efficient of friction
between the road surface and tires is extremely low)
²The VSS signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate)
²If the actual speed is not within 20 mph of the
set speed
The previous disengagement conditions are pro-
grammed for added safety.
Once the speed control has been disengaged,
depressing the ACCEL switch when speed is greater
than 25 mph restores the vehicle to the target speed
that was stored in the PCM.
NOTE: Depressing the OFF switch will erase the
set speed stored in the PCM's RAM.
While the speed control is engaged, the driver can
increase the vehicle speed by depressing the ACCEL
switch. The new target speed is stored in the PCM
when the ACCEL is released. The PCM also has a
9tap-up9feature in which vehicle speed increases at a
rate of approximately 2 mph for each momentary
switch activation of the ACCEL switch. The PCM
also provides a means to decelerate without disen-
gaging speed control. To decelerate from an existing
recorded target speed, depress and hold the COAST
switch until the desired speed is reached, then
release the switch.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION
Transmission control software includes an auto-
matic speed control overspeed reduction feature. This
maintains vehicle speed at the selected set point
when descending a grade.
The Transmission Control Module (TCM) first
senses that the speed control is set. If the set speedis exceeded by more than 4 mph (6.5 km/hr) and the
throttle is closed, the TCM causes the transaxle to
downshift to THIRD gear. After downshifting, the
automatic speed control resumes normal operation.
To ensure that an upshift is appropriate after the set
speed is reached, the TCM waits until the speed con-
trol system opens the throttle at least 8 degrees
before upshifting to OVERDRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the TCM maintains this gear until
the driver opens the throttle at least 8 degrees to
avoid an inappropriate upshift. The upshift is also
delayed for 0.5 seconds after reaching the 8 degrees
throttle opening in anticipation that the driver might
open the throttle enough to require THIRD gear.
This will avoid unnecessary and disturbing transmis-
sion cycling. If the automatic speed control RESUME
feature is used after braking, the upshift is delayed
until the set speed is achieved to reduce cycling and
provide better response.
STOP LAMP SWITCH
Vehicles equipped with the speed control option use
a dual function stop lamp switch. The switch is
mounted on the brake pedal mounting bracket under
the instrument panel. The PCM monitors the state of
the dual function stop lamp switch. Refer to Group 5,
Brakes for more information on stop lamp switch ser-
vice and adjustment procedures.
SERVO CABLE
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage. This cable causes the
throttle control linkage to open or close the throttle
valve in response to movement of the vacuum servo
diaphragm.
POWERTRAIN CONTROL MODULE
The speed control electronic control circuitry is
integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compart-
ment. The PCM speed control functions are moni-
tored by the On-Board Diagnostics (OBD). All OBD-
sensed systems are monitored by the PCM. Each
monitored circuit is assigned a Diagnostic Trouble
Code (DTC). The PCM will store a DTC in electronic
memory for any failure it detects. See On-Board
Diagnostic Tests in this group for more information.
The PCM cannot be repaired and must be replaced if
faulty.
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE ORGINAL VEHICLES MILAGE. IF THIS
8H - 2 VEHICLE SPEED CONTROL SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

SERVO VACUUM TEST
(1) Turn ignition switch to the ON position with-
out starting engine. Activate speed control ON
switch.
(2) Disconnect the four-way electrical connector
and the vacuum harness at the servo (Fig. 3).
(3) Connect a jumper wire from Pin 3 of the servo
to Pin 3 of the wire connector.
(4) Ground Pins 2 and 4 in the servo. Do not con-
nect pin 1.
(5) Connect a hand held vacuum pump to the vac-
uum nipple and apply 10 - 15 inches of vacuum.
(6) If servo pulls cable, replace servo.
(7) Ground Pin 1 on servo.
(8) Check that the throttle cable pulls in and holds
as long as the vacuum pump is connected. After one
minute, check if cable is still holding. If cable does
not hold replace the servo.
(9) Disconnect jumper from pin 3. Cable should
return to rest position. If not, replace servo.
(10) Connect 4 way electrical connector and vac-
uum harness to servo.
SPEED CONTROL SWITCH TEST
Refer to the appropriate Powertrain Diagnostic
Manual for switch test valves.
STOP LAMP SWITCH TEST
(1) Remove the stop lamp switch refer to Stop
Switch Removal/Installation in this section. Discon-
nect connector from stop lamp switch (Fig. 4). Using
an ohmmeter, switch continuity may be checked as
follows:
(2) With switch plunger released, there should be
continuity between Pin 5 and Pin 6.(3) With switch plunger depressed, there should be
continuity:
²Between Pin 1 and Pin 2.
²Between Pin 3 and Pin 4.
(4) If the above results are not obtained, the stop
lamp switch is defective or out of adjustment.
(5) Stop lamp switch adjustment is detailed in
Group 5, Brakes.
ELECTRICAL TESTS AT POWERTRAIN CONTROL
MODULE
(1) Unplug the GRAY 40-way connector from the
Powertrain Control Module (PCM), (Fig. 5).
(2) Remove both steering wheel speed control
switches and disconnect the wire connectors.
Fig. 3 Servo Harness Connector
Fig. 4 Stop Lamp Wiring
Fig. 5 Powertrain Control Module Location
8H - 6 VEHICLE SPEED CONTROL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)