1996 CHRYSLER VOYAGER brake fluid

(5) With the aid of a helper, apply pressure to the
brake pedal until a pressure of 6895 kPa (1000 psi) is
obtained on the proportioning valve inlet gauge.
Then based on the type of brake system the vehicle is
equipped with and the pressure specification shown
on the following table, compare the pressure reading
on the outlet gauge to the specification. If outlet
pressure at the proportioning valve is not within
specification when required inlet pressure is
obtained, replace the proportioning valve.
(6) Remove the pressure test fittings and pressure
gauges from the proportioning valve.
(7) Install the chassis brake lines in the correct
ports of the proportioning valve.
(8) Install the pressure test fittings and pressure
gauges in the opposite inlet and outlet port of the
height sensing proportioning valve. Repeat steps 4
and 5 for the other proportioning valve.
(9) Remove the pressure test fittings and pressure
gauges from the proportioning valve.
(10) Install the chassis brake lines in the correct
ports of the proportioning valve.
(11) Install the actuator (Fig. 22) on the height
sensing proportioning valve. Adjust the proportioning
valve actuator. See Height Sensing Proportioning
Valve in the Adjustment Section in this group of the
service manual for the adjustment procedure.
(12) Bleed both rear hydraulic circuits at the rear
brakes.
(13) Road test vehicle.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteri-
orated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
RED BRAKE WARNING LAMP TEST
For diagnosis of specific problems with the red
brake warning lamp system, refer to Brake System
Diagnostics Chart 2, located in the Diagnosis And
Testing section in this group of the service manual.
TRACTION CONTROL LAMP TEST
The traction control light is tested by cycling the
traction control switch on and off. The traction con-
trol switch used on this vehicle is a momentary con-
tact type switch. The test procedure for the traction
control light is performed as follows: Press the trac-
tion control switch once and the ªTrac Offº lamp will
illuminate. With the ªTrac Offº lamp illuminated,
press the traction control switch again and the ªTrac
Offº lamp will turn off.
If the traction control lamp does not function as
described in the test above, diagnosis of the traction
control switch, lamp, wiring and other related compo-
nents of the traction control system is required.
STOP LAMP SWITCH TEST PROCEDURE
The required procedure for testing the stop lamp
switch is covered in Group 8H, Vehicle Speed Control
System in this service manual. The electrical circuit
tests for stop lamps is covered in Group 8W Rear-
Lighting in this service manual.
WHEEL
BASEDRIVE
TRAINSALES CODEBRAKE SYS-
TEMSPLIT POINT SLOPEINLET PRES-
SURE PSIOUTLET
PRESSURE
PSI
SWB FWD BRA+BGF149DISC/DRUM
W/O ANTILOCKVAR. .30 1000 PSI 250-350 PSI
SWB FWDBRA+BGF
BRB+BGF
BRV+BGF149,159,159HD
DISC/DRUM
WITH ANTILOCK25 BAR .59 1000 PSI660-780
PSI
LWB FWD BRA+BGF149DISC/DRUM
W/O ANTILOCKVAR. .30 1000 PSI 250-350 PSI
LWB FWDBRA+BGF
BRB+BGF
BRV+BGF149,159,159HD
DISC/DRUM
WITH ANTILOCK25 BAR .59 1000 PSI 660-780 PSI
SWB AWD BRE+BGF159DISC/DISC
WITH ANTILOCK25 BAR .36 1000 PSI 525-640 PSI
LWB AWD BRE+BGF159DISC/DISC
WITH ANTILOCK41 BAR .36 1000 PSI 690-800 PSI
NSBRAKES 5 - 19
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Master cylinder reservoirs are marked with the
words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder (Fig. 26).
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.When filling master
cylinder fluid reservoir do not fill the filler
neck of the fluid reservoir (Fig. 26) with brake
fluid.
Use only Mopartbrake fluid or an equivalent from
a sealed container. Brake fluid must conform to DOT
3, specifications.
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid ect.
BLEEDING BASE BRAKE HYDRAULIC SYSTEM
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, refer to the
ITT Teves Mark 20 Antilock Brake System bleeding
procedure in the antilock brakes section of this ser-
vice manual.
PRESSURE BLEEDING PROCEDURE
CAUTION: Before removing the master cylinder
cover, throughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
CAUTION: When pressure bleeding the brakes
hydraulic system the fluid reservoir filler neck must
be removed from the master cylinder fluid reservoir.
Failure to remove the filler neck from the fluid res-
ervoir, may result in the filler neck separating from
the fluid reservoir when the hydraulic system is
pressurized.
Follow pressure bleeder manufacturer's instruc-
tions, for use of pressure bleeding equipment.
When bleeding the brake system, some air may be
trapped in the brake lines or valves far upstream, as
much as ten feet from the bleeder screw (Fig. 27).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes to
ensure all the air gets out.
(1) Remove the filler neck from the master cylin-
der fluid reservoir.
(2) Install the Adapter Master Cylinder Pressure
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 28). Attach the fluid hose
from the pressure bleeder to the fitting on Special
Tool 6921.
(3) Attach a clear plastic hose to the bleeder screw
at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid.
Fig. 26 Master Cylinder Fluid Level Marks
Fig. 27 Trapped Air In Brake Fluid Line
5 - 20 BRAKESNS

NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
²Left Rear Wheel
²Right Front Wheel
²Right Rear Wheel
²Left Front Wheel
(4) Open the left rear wheel bleeder screw at least
one full turnor more to obtain an adequate flow of
brake fluid (Fig. 29).
CAUTION: Just cracking the bleeder screw often
restricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
(5) After 4 to 8 ounces of brake fluid has been bled
through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate agood bleed of the hydraulic system has been
obtained.
(6) Repeat the procedure at all the other remain-
ing bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been improved,
enough fluid has not passed through the system to
expel all the trapped air. Be sure to monitor the fluid
level in the pressure bleeder, so it stays at a proper
level so air will not enter the brake system through
the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
BLEEDING WITHOUT A PRESSURE BLEEDER
NOTE: Correct manual bleeding of the brakes
hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the
manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of
the brake hydraulic system, correctly adjust the
rear brakes.
NOTE: The following wheel sequence should be
used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake
hydraulic system.
²Left Rear Wheel
²Right Front Wheel
²Right Rear Wheel
²Left Front Wheel
(1) Pump the brake pedal three or four times and
hold it down before the bleeder screw is opened.
(2) Push the brake pedal toward the floor and hold
it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens the
brake pedal will drop all the way to the floor.
(3) Release the brake pedal onlyafterthe bleeder
screw is closed.
(4) Repeat steps 1 through 3, four or five times, at
each bleeder screw in the required sequence. This
should pass a sufficient amount of fluid to expel all
the trapped air from the brake system. Be sure to
monitor the fluid level in the master cylinder, so it
stays at a proper level so air will not enter the brake
system through the master cylinder.
(5) Perform a final adjustment of the rear brake
shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.Fig. 28 Pressure Bleeding Cap Installed On Master
Cylinder
Fig. 29 Rear Wheel Cylinder Bleeder Screw
NSBRAKES 5 - 21
SERVICE PROCEDURES (Continued)

MASTER CYLINDER BLEEDING PROCEDURE
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange,
do not clamp on primary piston, seal\boot or body
of master cylinder.
(1) Clamp the master cylinder in a vise using only
the mounting flange (Fig. 30).
NOTE: Two different size bleeding tubes are used
depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with
traction control use a center port master cylinder
with a larger diameter brake tube. Vehicles not
equipped with traction control use a compensating
port master cylinder using a standard 3/16 inch
diameter brake tube. Be sure the correct size bleed-
ing tubes are used when bleeding the master cylin-
der.
(2) Install the Bleeding Tubes, Special Tool 6920
for a non traction control master cylinder or Special
Tool 8129 for a traction control master cylinder on
the master cylinder (Fig. 102). Position bleeding
tubes so the outlets of bleeding tubes will be below
surface of brake fluid when reservoir is filled to its
proper level.
(3) Fill brake fluid reservoir with brake fluid con-
forming to DOT 3 specifications such as Mopar or an
Equivalent.
(4) Using a wooden dowel, depress push rod slowly,
and then allow pistons to return to released position.
Repeat several times until all air bubbles are
expelled from master cylinder.
(5) Remove bleeding tubes from master cylinder
outlet ports, and then plug outlet ports and install
fill cap on reservoir.
(6) Remove master cylinder from vise.(7) Install the filler cap from the master cylinder
filler neck, on the master cylinder fluid reservoir.
(8) Install the master cylinder assembly on the
power brake vacuum booster.
NOTE: Note: It is not necessary to bleed the ABS
hydraulic control unit (HCU) after replacing the
master cylinder. But, the base brake hydraulic sys-
tem must be bled to ensure no air is entered the
hydraulic system when the master cylinder was
removed.
ROTOR MACHINING (FRONT/REAR)
BRAKE ROTOR MACHINING PROCEDURES
Any servicing of the rotor requires extreme care to
maintain the rotor to within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be resurfaced,
refaced (Fig. 32) or (Fig. 33) or replaced.
NOTE: All rotors have markings for minimum
allowable thickness cast on an un-machined sur-
face of the rotor (Fig. 34) or (Fig. 35).
This marking includes 0.76 mm (0.030 inch) allow-
able rotor wear beyond the recommended 0.76 mm
(0.030 inch) of rotor refacing.
The collets, shafts and adapters used on the brake
lathe and the bearing cups in the rotor MUST be
clean and free from any chips or contamination.
When mounting the rotor on the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
If the rotor is not mounted properly, the lateral
runout will be worse after refacing or resurfacing
than before.
Fig. 30 Master Cylinder Mounted In Vise
Fig. 31 Bleed Tubes Installed On Master Cylinder
5 - 22 BRAKESNS
SERVICE PROCEDURES (Continued)

flared end tubing.PLACE TUBE NUT ON TUB-
ING BEFORE FLARING THE TUBING.
DOUBLE INVERTED TUBING FLARES
To make a double inverted tubing flare (Fig. 39)
and (Fig. 40). Open handles of Flaring Tool, Special
Tool C-4047 or equivalent. Then rotate jaws of tool
until the mating jaws of tubing size are centered
between vertical posts on tool. Slowly close handles
with tubing inserted in jaws but do not apply heavy
pressure to handle as this will lock tubing in place.Place gauge (Form A) on edge over end of brake
tubing. Push tubing through jaws until end of tubing
contacts the recessed notch in gauge matching the
tubing size. Squeeze handles of flaring tool and lock
tubing in place. Place 3/16 inch plug of gauge (A)
down in end of tubing. Swing compression disc over
gauge and center tapered flaring screw in recess of
disc. Screw in until plug gauge has seated on jaws of
flaring tool. This action has started to invert the
extended end of the tubing. Remove gauge and con-
tinue to screw down until tool is firmly seated in tub-
ing. Remove tubing from flaring tool and inspect
seat. Refer to tube routing diagrams for proper brake
tube routing and clip locations. Replace any damaged
tube routing clips.
ISO TUBING FLARES
CAUTION: All ISO style tubing flares (Fig. 39) and
(Fig. 40) are of metric dimensions. When performing
any service procedures on vehicles using ISO style
tubing flares, metric size tubing of 4.75 mm MUST
be used with metric ISO tube flaring equipment.
To create a (metric) ISO style tubing flare, Use
Snap-On Flaring Tool TFM-428, or equivalent. See
(Fig. 41) and proceed with the steps listed below.Be
sure to place the tubing nut on the tube before
flaring the tubing.
(1) Carefully prepare the end of the tubing to be
flared. Be sure the end of the tubing to be flared is
square and all burrs on the inside of the tubing are
removed (Fig. 38).This preparation is essential to
Fig. 37 Cutting And Flaring Of Brake Fluid Tubing
Fig. 38 Brake Fluid Tube Preparation For Flaring
Fig. 39 Hydraulic Brake Tubing Flare Styles
NSBRAKES 5 - 25
SERVICE PROCEDURES (Continued)

(3) Remove the 2 caliper to steering knuckle guide
pin bolts (Fig. 44).
(4) Remove caliper from steering knuckle, by first
rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
45).
(5) Support caliper firmly to prevent weight of cal-
iper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake fluid
flex hose, can damage the flexible brake hose (Fig.
46).
INSTALL
(1) Lubricate both steering knuckle abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or equivalent.CAUTION: Use care when installing the caliper
assembly onto the steering knuckle, so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(2) Carefully position caliper and brake pad
assemblies over brake rotor by hooking lower or
upper end of caliper over the machined abutment on
steering knuckle (Fig. 45). Then rotate caliper into
position at the top of the steering knuckle (Fig. 45).
Make sure that caliper guide pin bolts, bushings and
sleeves are clear of the steering knuckle bosses.
(3) Install the caliper guide pin bolts (Fig. 44) and
tighten to a torque of 41 N´m (40 ft. lbs.).Extreme
caution should be taken not to cross thread the
caliper guide pin bolts.
(4) Install the wheel and tire assembly.
(5) Using a torque wrench, tighten the wheel
mounting stud nuts in proper sequence until all nuts
are torqued to half specification. Then repeat the
tightening sequence to the full specified torque of 135
N´m (100 ft. lbs.).
(6) Remove jackstands or lower hoist.
(7)Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a
firm brake pedal.
REAR DISC BRAKE CALIPER
During service procedures, grease or any other for-
eign material must be kept off brake shoe assem-
blies, and braking surfaces of rotor.
Handling of the rotor and caliper, must be done in
such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
If inspection reveals that the caliper piston seal is
leaking, itMUSTbe replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
Fig. 44 Removing Caliper Guide Pin Bolts
Fig. 45 Caliper Assembly Mounting On Steering
Knuckle (Typical)
Fig. 46 Storing Front Disc Brake Caliper
5 - 28 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(6) Remove the rear rotor from the hub by pulling
it straight off the wheel mounting studs.
(7) Remove the outboard brake shoe from the cali-
per. Brake shoe is removed by prying brake shoeretaining clip over raised area on caliper and sliding
the brake shoe off the caliper.
(8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 58).
CALIPER INSPECTION
Check for piston seal leaks (brake fluid in and
around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged,
or fluid leak is visible, disassemble caliper assembly
and install a new seal and boot, (and piston if
scored). Refer to procedures titled Disc Brake Caliper
Disassembly.
Check the caliper dust boot and caliper pin bush-
ings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brit-
tle. Refer to Cleaning And Inspection Of Brake Cali-
per.
INSTALL
NOTE: Step 1 below is only required when install-
ing a caliper after new brake shoes have been
installed.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments with a lib-
eral amount of MopartMultipurpose Lubricant, or
equivalent.
(3) If removed, install the rear rotor on the hub,
making sure it is squarely seated on the face of the
hub.
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston
(Fig. 59).
Fig. 55 Caliper Guide Pin Bolts
Fig. 56 Removing / Installing Caliper
Fig. 57 Correctly Supported Caliper
Fig. 58 Removing Inboard Brake Shoe
5 - 32 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.
(8) If hub/bearing cannot be removed from the axle
by hand, use Remover Special Tool 8214 (Fig. 76) and
following procedure to press the hub/bearing out of
the axle.
(a) Place Special Tool 8214-1 over tone wheel
and against cast flange of hub/bearing (Fig. 76)
(b) Put a dab of grease in the bolt pilot hole on
the back of Special Tool 8214-1.
(c) Insert Special Tool 8214-2 into the hole in the
bottom of the end casting on the axle (Fig. 76).
Special Tool 8214-2 should be against and sup-
ported by the axle plate (Fig. 76) when pressing
the wheel bearing out of the axle.If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
(d) Align bolt in Special Tool 8214-2 with pilot
hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1.
(e) Press hub/bearing out of axle by continuing
to tighten bolt in Special Tool 8214-2 against Spe-
cial Tool 8214-1.
(9) Remove the hub/bearing from the rear axle and
brake support plate (Fig. 77).
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 78) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate.(11) Lower vehicle enough to access the brake
pedal.
(12) Using a brake pedal depressor, move brake
pedal to a position past its first 1 inch of travel. This
will prevent brake fluid from draining out of master
cylinder when brake tube is remove from wheel cyl-
inder.
(13) Raise vehicle.
(14) Disconnect brake tube from wheel cylinder
(Fig. 79).
(15) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate (Fig. 79).
(16) Remove the wheel cylinder from the brake
support plate.
(17) Remove the rear brake support plate from the
rear axle.
Fig. 76 Special Tool 8214 Installed
Fig. 77 Hub/Bearing Removal And Installation On
Axle
Fig. 78 Removing Park Brake Cable From Brake
Support Plate
5 - 38 BRAKESNS
REMOVAL AND INSTALLATION (Continued)