1996 CHRYSLER VOYAGER brake fluid

INSTALL
(1) Install the 4 hub/bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 80).
NOTE: When installing the hub/bearing on the rear
axle, the bearing is to be installed with the thick
bearing mounting flange (Fig. 77) pointing down.
(3) Align the rear hub/bearing with the 4 mount-
ing bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and
squarely seated onto flange of rear axle.
(4) Tighten the 4 hub/bearing mounting bolts (Fig.
75) to a torque of 129 N´m (95 ft. lbs.)(5) Apply sealant such as Mopar Gasket-In-A-Tube
or an equivalent around the wheel cylinder opening
in the brake support plate.
(6) Install wheel cylinder onto brake support and
tighten the wheel cylinder to brake support plate
attaching bolts (Fig. 79) to 8 N´m (75 in. lbs.).
(7) Install brake tube (Fig. 79) on rear wheel cyl-
inder. Tighten tube nut to a torque of 16 N´m (142 in.
lbs.).
(8) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 74). Install the speed sensor
attaching bolt and tighten to a torque of 12 N´m (105
in. lbs.).
(9) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(10) Install the park brake cable on the park brake
actuation lever.
(11) Install the rear brake shoes on the brake sup-
port plate. Refer to Brake Shoe Service in this sec-
tion of the service manual for the proper brake shoe
installation procedure.
(12) Install brake drum onto hub/bearing.
(13) Install wheel and tire.
(14) Tighten wheel stud nuts to 129 N´m (95 ft.
lbs.).
(15) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
(16) Bleed the entire brake system. See Bleeding
Brake System in the Service Procedures section in
this group of the service manual.
REAR BRAKE WHEEL CYLINDER
REMOVE
(1) In case of a leak, remove brake shoes, (replace
if soaked with grease or brake fluid.)
(2) Disconnect the rear brake hydraulic tube from
the wheel cylinder (Fig. 81).
Fig. 79 Rear Wheel Cylinder Mounting Bolts And
Brake Tube
Fig. 80 Brake Support Plate Mounted On Bearing
Attaching Bolts
Fig. 81 Brake Hydraulic Tube At Wheel Cylinder
NSBRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)

caliper adapter and hub/bearing are squarely seated
against the axle. Then tighten the hub/bearing
mounting bolts to a torque of 129 N´m (95 ft. lbs.).
(3) Install driveshaft in hub/bearing and on output
shaft of rear drive line module. Driveshaft is
installed by first sliding the outer joint of the drive-
shaft into the hub/bearing and then compressing the
inner joint on the driveshaft and installing it on the
output shaft the drive line module.
(4) Install rotor on hub/bearing.
(5) Carefully lower disc brake caliper and brake
shoes over rotor and onto caliper adapter by revers-
ing the removal procedure (Fig. 92).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(6) Install the disc brake caliper guide pin bolts
(Fig. 91). Tighten the guide pin bolts to a torque of
22 N´m (192 in. lbs.).
(7) Clean all foreign material off the threads of the
outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 88) on the stub shaft of the outer C/V
joint.
(8) Lower vehicle.
(9) Set the park brake.This is required to keep
the driveshaft from rotating when tightening
and torquing the hub nut and driveshaft inner
joint to driveline module mounting nuts.
(10) Raise vehicle.
(11) Tighten the driveshaft inner joint to drive line
module output shaft mounting bolts (Fig. 89) to a
torque of 61 N´m (45 ft. lbs.).
(12) Tighten the outer C/V joint hub nut (Fig. 88)
to a torque of 244 N´m (180 ft. lbs.).
(13) Install the spring washer (Fig. 87) on the stub
shaft of the outer C/V joint.
(14) Install the nut retainer and cotter pin (Fig.
86) on the stub shaft of the outer C/V joint.
(15) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 90). Tighten the wheel speed sen-
sor attaching bolt to a torque of 12 N´m (105 in. lbs).
(16) Install wheel and tire.
(17) 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 129 N´m (95 ft. lbs.).
(18) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(19) Road test vehicle to ensure proper operation
of the brake system.MASTER CYLINDER
CAUTION: Different types of master cylinders are
used on this vehicle. Vehicles equipped with trac-
tion control use a center port master cylinder. Vehi-
cles not equipped with traction control use a
compensating port master cylinder. Be sure to ver-
ify if the vehicle is equipped with traction control
and that the correct replacement master cylinder is
used. Also, vehicles that are equipped with four
wheel disc brakes have a master with a different
size piston bore than the other master cylinders. If
a new master cylinder is being installed, be sure
the correct master cylinder is used for the type of
brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary 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 the brake
pedal until a firm pedal is achieved (4-5 strokes).
CAUTION: Before removing the master cylinder
filler tube from the brake fluid reservoir, the filler
tube, brake fluid reservoir and master cylinder must
be thoroughly cleaned. This must be done to pre-
vent dirt particles from falling into the brake fluid
reservoir and entering the brakes hydraulic system.
(2) Thoroughly clean all surfaces of the filler neck,
brake fluid reservoir, and master cylinder. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent.
(3) Remove master cylinder filler tube from brake
fluid reservoir by pushing down and rotating (Fig.
97). Then remove the cap from the removed filler
tube and install it on the master cylinder reservoir.
(4) Remove vehicle wiring harness connector, from
the brake fluid level sensor, in master cylinder brake
fluid reservoir (Fig. 98).
(5) Disconnect the primary and secondary brake
tubes from the master cylinder housing (Fig. 99).
Install sealing plugs in the open brake tube outlets
on master cylinder assembly.
5 - 44 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughlycleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(6) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
(7) Remove the 2 nuts attaching the master cylin-
der assembly to the brake vacuum booster (Fig. 100).
(8) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: The master cylinder is used to create
the seal for holding vacuum in the power brake vac-
uum booster. The vacuum seal/boot on the master
cylinder MUST be replaced whenever the master
cylinder is removed from the power brake vacuum
booster.
(9) Remove the vacuum seal located on the mount-
ing flange of the master cylinder. The vacuum seal is
removed from the master cylinder bycarefullypull-
ing it away from the master cylinder.Do not
attempt to pry the seal off the master cylinder
by inserting a sharp tool between seal and mas-
ter cylinder casting.
BLEEDING MASTER CYLINDER
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange,
do not clamp on primary piston, seal or body of
master cylinder.
(1) Clamp the master cylinder in a vise using only
the mounting flange (Fig. 101).
Fig. 97 Master Cylinder Filler Tube Removal
Fig. 98 Electrical Connector At Fluid Level Sensor
Fig. 99 Primary/Secondary Brake Tubes At Master
Cylinder
Fig. 100 Master Cylinder Mounting To Vacuum
Booster
NSBRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)

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, (Fig. 102) 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.
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.
INSTALL
CAUTION: When replacing the master cylinder on
a vehicle, a NEW vacuum seal MUST be installed on
the master cylinder. Use only procedure detailed
below for installing the vacuum seal onto the mas-
ter cylinder.
(1) Install aNEWvacuum seal on master cylinder
making sure seal sits squarely in groove of master
cylinder casting (Fig. 103).
(2) Position master cylinder on studs of power
brake unit, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(3) Install the 2 master cylinder to power brake
unit mounting nuts. Then tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
Fig. 101 Master Cylinder Correctly Mounted In Vise
Fig. 102 Bleeding Tubes Installed On Master
Cylinder
Fig. 103 Vacuum Seal Installed On Master Cylinder
5 - 46 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: When installing the primary and second-
ary brake tubes on master cylinder, be sure brake
tubes do not contact any other components within
the vehicle and that there is slack in the flexible
sections of the tubes. This is required due to the
movement between the ABS hydraulic control mod-
ule (HCU) and the master cylinder, when the vehicle
is in motion.
(4) Connect the primary and secondary brake
tubes to master cylinder primary and secondary
ports (Fig. 99). Brake tubes must be held securely
when tightened to control orientation of flex section.
Then fully tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
(5) Install the vehicle wiring harness connector, on
the brake fluid level sensor in the master cylinder
brake fluid reservoir (Fig. 98).
(6) Install filler tube into the master cylinder fluid
reservoir (Fig. 97).
VACUUM BOOSTER 2.4 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping 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 (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 104)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 105)
attaching the battery tray to the body.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 106).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Useonly a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
(10) Remove clip attaching drain hose for wiper
module to brake tube at master cylinder. Remove
Fig. 104 Air Inlet Resonator
Fig. 105 Battery Tray Mounting Locations
Fig. 106 Fluid Level Sensor Electrical Connection
NSBRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)

(7) Install aNEWvacuum seal on mounting flange
of master cylinder (Fig. 110).
(8) Position master cylinder on studs of vacuum
booster aligning push rod on vacuum booster with
master cylinder piston.
(9) Install the 2 nuts (Fig. 107) mounting the mas-
ter cylinder to the vacuum booster. Tighten the
mounting nuts to a torque of 25 N´m (225 in. lbs.).
(10) Install the wiper module drain hose (Fig. 107)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to the brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(11) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 106).
(12) Install the battery tray in the vehicle. Install
the 2 bolts and the nut (Fig. 105) attaching the bat-
tery tray. Tighten the 2 bolts and the nut to a torque
of 14 N´m (125 in lbs.).(13) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(14) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(15) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 104). Securely tighten the hose clamp at the
air cleaner housing and throttle body.
(16) Install the battery and the battery thermal
guard.
(17) Install the battery cables on the battery.
(18) Check the operation of the stop lamp switch
and adjust if necessary.
VACUUM BOOSTER 3.0 LITER ENGINE
REMOVE
CAUTION: Stored vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary 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 the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 111)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 112)
attaching the battery tray to the body of the vehicle.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 113).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Fig. 109 Retaining Clip Installed On Brake Pedal Pin
Fig. 110 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

(10) Remove clip attaching drain hose to brake
tube at master cylinder. Remove drain hose (Fig. 114)
from wiper module. Remove the 2 nuts attaching the
master cylinder assembly to the power brake vacuum
booster (Fig. 114).
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the power brake vacuum
booster.
(11) Remove the master cylinder and the brake
tubes as an assembly from power brake vacuum
booster. When master cylinder is removed, lay it out
of the way on top of the left motor mount(12) Disconnect vacuum hose from check valve
located on power brake vacuum booster.DO NOT
REMOVE CHECK VALVE FROM POWER
BRAKE BOOSTER.
(13) Locate the power brake vacuum booster input
rod to brake pedal attachment under instrument
panel. Position a small screwdriver between the cen-
ter tang on the power brake booster input rod to
brake pedal pin retaining clip (Fig. 115).
(14) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assembled.
(15) Remove the 4 nuts attaching the vacuum
booster to the dash panel. Nuts are accessible from
under dash panel in area of the steering column and
pedal bracket assembly.
(16) From outside the vehicle, slide power brake
vacuum booster forward until its mounting studs
Fig. 111 Air Inlet Resonator
Fig. 112 Battery Tray Mounting Locations
Fig. 113 Electrical Connection To Fluid Level Sensor
Fig. 114 Master Cylinder Attachment To Power
Brake Vacuum Booster
5 - 50 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(11) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 113).
(12) Install the battery tray in the vehicle. Install
the 2 bolts and the nut (Fig. 112) attaching the bat-
tery tray to the vehicle. Tighten the 2 bolts and the
nut to a torque of 14 N´m (125 in lbs.).
(13) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(14) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(15) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 111). Securely tighten the hose clamp at the
air cleaner housing and throttle body.
(16) Install the battery and the battery thermal
guard.
(17) Install the battery cables on the battery.
(18) Check the operation of the stop lamp switch
and adjust if necessary.
VACUUM BOOSTER 3.3/3.8 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping the
brake pedal, with the vehicle's engine not running,
until a firm feeling brake pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 118)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 119)
attaching the battery tray to the body of the vehicle.(8) Remove the wiring harness connector (Fig. 120)
from the EGR valve transducer.
(9) Remove wiring harness connectors from throt-
tle position sensor and AIS motor on throttle body
(Fig. 121).
(10) Remove the 2 bolts (Fig. 122) attaching the
throttle body to the intake manifold and the clip (Fig.
122) attaching the wiring harness to the throttle
cable bracket. Then remove the throttle body and
throttle cable bracket as an assembly from the intake
manifold.
(11) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 123).
(12) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
Fig. 118 Air Inlet Resonator
Fig. 119 Battery Tray Mounting Locations
5 - 52 BRAKESNS
REMOVAL AND INSTALLATION (Continued)