1996 CHRYSLER VOYAGER Service Manual

CONTROLLER ANTILOCK BRAKES (CAB)
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(4) Remove the 25 way connector (Fig. 25) from
the CAB located on the bottom of the HCU. The 25
way connector is removed from the CAB using the
following procedure. Grasp the lock on the 25 way
connector (Fig. 25) and pull it as far out as possible
(Fig. 26). This will unlock and raise the 25 way con-
nector from the socket on the CAB.
CAUTION: Before removing the brake tubes from
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(5) Thoroughly clean all surfaces of the HCU, and
all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(6) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 27).(7) Remove the 3 bolts (Fig. 28) attaching the
HCU mounting bracket to the front suspension cross-
member.
Fig. 25 CAB 25 Way Connector
Fig. 26 Unlocking CAB 25 Way Connector
Fig. 27 Brake Tube Connections To HCU
Fig. 28 HCU To Suspension Cradle Mounting Bolts
NSBRAKES 5 - 103
REMOVAL AND INSTALLATION (Continued)

(8) Remove HCU and the mounting bracket as a
unit from the vehicle.
(9) Remove the 3 bolts (Fig. 29) mounting the
HCU to the mounting bracket. Separate the HCU
from the mounting bracket.
(10) Unplug the pump motor wiring harness (Fig.
30) from the CAB.
(11) Remove the 4 bolts (Fig. 31) attaching the
CAB to the valve block of the HCU.
(12) Remove the CAB from the valve block of the
HCU (Fig. 32).
INSTALL
(1) Install the CAB (Fig. 32) on the valve block of
the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 31)
to the valve block of the HCU. Tighten the CAB
mounting bolts to a torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 30).(4) Install the HCU on the mounting bracket (Fig.
29). Install the 3 bolts (Fig. 29) attaching the HCU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The HCU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the HCU bracket to the front suspen-
sion crossmember.
(5) Install the HCU and its mounting bracket as
an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember (Fig. 28). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
Fig. 29 HCU Mounting Bolts
Fig. 30 Pump Motor To CAB Wiring Harness
Fig. 31 CAB Attaching Bolts
Fig. 32 Remove/Install CAB
5 - 104 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Because of the flexible section in the
primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 27) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(6) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 27). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(7) Install the 25 way connector on the CAB using
the following procedure. Position the 25 way connec-
tor in the socket of the CAB and carefully push it
down as far as possible. When connector is fully
seated by hand into the CAB socket, push in the con-
nector lock (Fig. 26). This will pull the connector into
the socket of the CAB and lock it in the installed
position.
(8) Install the routing clips (Fig. 33) on the brake
tubes.(9) Lower vehicle.
(10) Connect negative cable back on negative post
of the battery.
(11) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.
(12) Road test vehicle to ensure proper operation
of the base and ABS brake systems.
WHEEL SPEED SENSOR (FRONT)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove the 2 screws (Fig. 34) attaching front
channel bracket and grommet retainer to the outer
frame rail.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Pull speed sensor cable grommet and connector
through the hole in the strut tower (Fig. 35). Discon-
nect speed sensor cable from vehicle wiring harness
(Fig. 35).
(5) Remove the wheel speed sensor head to steer-
ing knuckle attaching bolt (Fig. 36).
(6) Remove sensor head from steering knuckle. If
the sensor has seized, due to corrosion,DO NOT
USE PLIERS ON SENSOR HEAD.Use a hammer
and a punch and tap edge of sensor ear, rocking the
sensor side to side until free.
Fig. 33 Brake Tube Routing Clips
Fig. 34 Front Speed Sensor Cable Channel Bracket
NSBRAKES 5 - 105
REMOVAL AND INSTALLATION (Continued)

(7) Remove the wheel speed sensor cable grommets
from the retaining bracket (Fig. 37).(8) Remove front wheel speed sensor assembly
from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts
and/or over extension of cables, resulting in an
open circuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector (Fig. 35). Be
sure speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then
insert cable and grommet into hole in strut tower
(Fig. 35).
CAUTION: When installing channel bracket, do not
pinch the speed sensor cable under the channel
bracket.
(2) Install the channel bracket and grommet
retainer on the frame rail (Fig. 34).
(3) Install the 2 bolts (Fig. 34) attaching the chan-
nel bracket to frame. Tighten the 2 attaching bolts to
a torque of 11 N´m (95 in. lbs.).
(4) Insert speed sensor cable grommets into inter-
mediate bracket on strut (Fig. 37). Route cable from
strut to steering knuckle on the rearward side of the
stabilizer bar link.
(5) Install the wheel speed sensor to steering
knuckle attaching bolt (Fig. 36). Tighten the speed
sensor attaching bolt to a torque of 12 N´m (105 in.
lbs.)
(6) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone-
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 in.).
(7) Install the wheel and tire assembly on vehicle.
(8) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
WHEEL SPEED SENSOR (REAR FWD)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
Fig. 35 Speed Sensor Cable To Vehicle Wiring
Harness
Fig. 36 Front Wheel Speed Sensor Attaching Bolt
Fig. 37 Front Wheel Speed Sensor Cable Routing
5 - 106 BRAKESNS
REMOVAL AND INSTALLATION (Continued)