1996 CHRYSLER VOYAGER wheel bolt torque

group of the service manual for the installation pro-
cedure.
(13) Install wheel and tire.
(14) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(15) Lower vehicle.
(16) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(17) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
PARK BRAKE CABLE ADJUSTMENT
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. See Rear Brake Adjust-
ment and Park Brake Shoe Adjustment in the Ser-
vice Adjustments Section in this group of the service
manual.
When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes.
When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
PROPORTIONING VALVE (HEIGHT SENSING)
Proportioning valve actuator adjustment will be
required if there is a complaint of premature rear
wheel lockup and the front and rear brake shoe lin-
ings checked OK during inspection, the height sens-
ing proportioning valve required replacement, or
there is a complaint of excessive pedal effort and the
vacuum booster and brake pedal checked OK. Make
sure the proportioning valve and the mounting
bracket are firmly attached to the vehicle. Then, pro-
ceed with the following procedure to perform the
adjustment of the actuator.(1) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or with a frame contact type
hoist so the rear suspension of the vehicle is hanging
free. See hoisting in the Lubrication And Mainte-
nance section of this service manual.
(2) Remove rear wheels/tires.
(3) Using an appropriate jack, support the rear
axle prior to the removal of the track bar and shock
absorber bolts from the rear axle.
(4) Unbolt the track bar from the rear axle.
(5) Unbolt both shock absorbers from the rear
axle.
(6) Loosen (do not remove) both of the leaf spring
to front spring hanger pivot bolts.
NOTE: When lowering the rear axle be sure that the
leaf springs do not come in contact with the hoist
limiting the downward movement of the axle. If this
occurs an improper adjustment of the actuator may
result.
(7) Lower the rear axle so it is at its farthest point
of downward movement.
(8) Loosen the adjustment nut (Fig. 203) on the
actuator.
(9) Be sure the hooked end of the actuator is cor-
rectly (fully) seated in the clip on the proportioning
valve lever and that the clip is correctly positioned
on the lever of the proportioning valve.
(10) Pull the housing of the proportioning valve
actuator toward the spring hanger (Fig. 203) until
the lever on the proportioning valve bottoms on the
body of the proportioning valve.Hold the propor-
tioning valve actuator in this position while
tightening the adjustment nut (Fig. 203) to a
torque of 5 N´m (45 in. lbs.). Proportioning
valve adjustment is now complete.
(11) Install shock absorbers and track bar on rear
axle.Do not tighten the mounting bolts for any
of the loosened suspension components at this
time.
(12) Install the wheel/tires.
Fig. 203 Proportioning Valve Actuator Adjustment
NSBRAKES 5 - 81
ADJUSTMENTS (Continued)

(13) Lower the vehicle to the ground.Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Tighten the spring to front hanger pivot bolts
to a torque of 156 N´m (115 ft. lbs.).
(15) Tighten the shock absorber mounting bolts to
a torque of 101 N´m (75 ft. lbs.).
(16) Tighten the track bar mounting bolt to a
torque of 95 N´m (70 ft. lbs.).
(17) Road test vehicle to ensure that the prema-
ture rear wheel lockup condition has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKESNS
ADJUSTMENTS (Continued)

BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
Antilock Brake Sytem (Teves Mark-20)...........
MASTER CYLINDER ASSEMBLY:
Supplier..............................Bosch
Type For Non-ABSAnd
ABS Brakes. . . .Conventional Compensating Port
Type For ABS Brakes
With Traction Control . . .Dual Center Port Design
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE /
STROKE AND SPLIT:
ABS W/Disc/Drum Brakes......23.8 mm x 36 mm
(.937 in. x 1.47 in.)
AWD W/Disc/Disc Brakes........25.4 mm x 39 mm
(1.00 in. x 1.50 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
Non-ABS And ABS . . .Primary 7/16±24 Secondary 7/
16±24
ABS With Traction Control.......Primary M12 x 1
Secondary M12 x 1
Outlet Fitting Type Non-ABS
AndABS...........Double Wall Inverted Flare
Outlet Fitting Type ABS With
Traction Control...................ISO Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type............ISO Flare
BOOSTER:
Make/Type.................Bosch Vacuum Assist
Mounting Studs.....................M8x1.25
Type .........................270 ZLT RSMV
Boost At 20 inches Of
Manifold Vacuum...........3800 N´m (850 lbs.)
PROPORTIONING VALVE:
Material...........................Aluminum
Function....................Hydraulic Pressure
Proportioning To Rear Brakes
BRAKE PEDAL
Pedal Ratio.............................3.36
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components..............17N´m(145 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
MASTER CYLINDER:
To Vacuum Booster
Mounting Nut............25N´m(225 in. lbs.)
FIXED PROPORTIONING VALVE:
To Frame Rail Attaching
Bolts....................14N´m(125 in. lbs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounting Bracket
Attaching Bolts...........23N´m(200 in. lbs.)
Actuator Assembly
Adjustment Nut.............5N´m(45in.lbs.)
Mounting Bracket To Frame
Rail Bolts................17N´m(150 in. lbs.)
JUNCTION BLOCK (NON-ABS BRAKES)
To Suspension Cradle
Mounting Bolt............28N´m(250 in. lbs.)
VACUUM BOOSTER:
To Dash Panel Mounting
Nuts....................28N´m(250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate Mounting
Bolts.....................8N´m(75in.lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Rear Axle Mounting Bolts . . .130 N´m (95 ft. lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts..............41N´m(30ft.lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
Mounting Bracket To
Suspension Cradle Bolts.....28N´m(250 in. lbs.)
To Mounting Bracket Isolator
Attaching Bolts............11N´m(97in.lbs.)
CAB To HCU Mounting Screws . . .2 N´m (17 in. lbs.)
WHEEL SPEED SENSOR:
To Axle Or Steering Knuckle
Mounting Bolt............12N´m(105 in. lbs.)
PARKING BRAKE:
Pedal Assembly Mounting
Bolts....................28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Axle Mounting Bolts........129 N´m (95 ft. lbs.)
WHEEL:
Stud Lug Nut........115±156 N´m (84-115 ft. lbs.)
NSBRAKES 5 - 83
SPECIFICATIONS (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)

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) Install wheel speed sensor head. Note, the plas-
tic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor
head attaching bolt, the plastic anti-rotation pin
must be fully seated into the bearing flange.
(2) Install the wheel speed sensor head to bearing
flange attaching bolt (Fig. 42). Tighten the attaching
bolt to a torque 12 N´m (105 in. lbs.)
(3) 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.).
(4) Install the 2 routing brackets attaching the
speed sensor cable and brake tube to the rear axle
(Fig. 41).The rear wheel speed sensor cable
should be routed under the rear brake tube
(Fig. 41).
CAUTION: When installing rear wheel speed sen-
sor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips.
Routing clips are molded onto the hose and will
require replacement of the brake flex hose if dam-
aged during installation of the wheel speed sensor
cable.(5) Install speed sensor cable into routing clips on
rear brake flex hose (Fig. 41).
(6) If installing a right rear speed sensor cable,
install the speed sensor cable grommet on the axle
brake flex hose bracket (Fig. 40).
CAUTION: The wheel speed sensor cable connec-
tors for the left and right rear wheel speed sensors
are keyed differently. Therefore, when connecting a
wheel speed sensor cable to the vehicle wiring har-
ness, do not force the connectors together. If the
connectors are forced together, damage to the con-
nectors will occur.
(7) Plug speed sensor cable connector into vehicle
wiring harness (Fig. 38).Be sure speed sensor
cable connector is fully seated and locked into
vehicle wiring harness connector.
(8) Install the speed sensor cable grommet into the
body, being sure the grommet is fully seated into the
body hole.
(9) Install the tire and wheel assembly on vehicle.
(10) Road test vehicle to ensure proper operation
of the base and ABS braking systems.
WHEEL SPEED SENSOR (REAR AWD)
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.
CAUTION: When unplugging speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also inspect
connectors for any signs of previous damage.
(3) Remove grommet from floor pan of vehicle and
unplug speed sensor cable connector from vehicle
wiring harness (Fig. 43).
CAUTION: When removing rear wheel speed sen-
sor cable from routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake flex hose if damaged dur-
ing removal of the speed sensor cable.
Fig. 42 Rear Wheel Speed Sensor Attaching Bolt
5 - 108 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(2) Install the wheel speed sensor head attaching
bolt (Fig. 46). Tighten the attaching bolt to a torque
12 N´m (105 in. lbs.)
(3) 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.).
(4) Install the routing brackets attaching the speed
sensor cable and brake tube to the rear axle (Fig.
45).The rear wheel speed sensor cable should
be routed under the rear brake tube (Fig. 45).
CAUTION: When installing rear wheel speed sen-
sor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips.
Routing clips are molded onto the hose and will
require replacement of the brake flex hose if dam-
aged during installation of the wheel speed sensor
cable.
(5) Install speed sensor cable into routing clips on
rear brake flex hose (Fig. 44).
CAUTION: The wheel speed sensor cable connec-
tors for the left and right rear wheel speed sensors
are keyed differently. Therefore, when connecting a
wheel speed sensor cable to the vehicle wiring har-
ness, do not force the connectors together. If the
connectors are forced together, damage to the con-
nectors will occur.
(6) Plug speed sensor cable connector into vehicle
wiring harness (Fig. 43).Be sure speed sensor
cable connector is fully seated and locked into
vehicle wiring harness connector.
(7) Install the speed sensor cable grommet into the
body, being sure the grommet is fully seated into the
body hole.
(8) Install the tire and wheel assembly on vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
TONE WHEEL (REAR FWD)
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual for required lifting procedure.
(2) Remove the wheel and tire assembly.
(3) Remove rear brake drum from the hub/bearing
assembly.
(4) Remove the rear wheel speed sensor from the
rear hub/bearing flange (Fig. 47). This will prevent
damage to the speed sensor during removal and
installation of the hub/bearing assembly.(5) Remove the 4 bolts (Fig. 48) attaching the hub/
bearing assembly to the flange of the rear axle.
(6) Remove the hub/bearing assembly from the
rear axle and brake support plate (Fig. 49).
Fig. 47 Rear Wheel Speed Sensor
Fig. 48 Rear Hub/Bearing Mounting Bolts
Fig. 49 Removing Rear Hub/Bearing From Axle
5 - 110 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(7) Install wheel lug nuts on 3 of the wheel mount-
ing studs to protect the stud threads from damage by
the vise jaws. Mount the hub/bearing assembly in a
vise (Fig. 50). Using Puller, Special Tool C-4693
installed as shown in (Fig. 50) remove the tone wheel
from the hub/bearing assembly.
INSTALL
(1) Place hub/bearing assembly in an arbor press
supported by Receiver, Special Tool, 6062A±3 (Fig.
51). Position Driver, Special Tool 6908±1 with under-
cut side facing up (Fig. 51) on top of the tone wheel.
(2) Press the tone wheel onto the hub/bearing
assembly until it is flush with the end of hub shaft
(Fig. 52).
(3) Install the 4 hub/bearing to axle flange mount-
ing bolts into the 4 mounting holes in the flange of
the rear axle.(4) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.
(5) Align the rear hub/bearing assembly with the 4
mounting bolts and start mounting bolts into hub/
bearing assembly. 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.
(6) Tighten the 4 hub/bearing mounting bolts (Fig.
48) to a torque of 129 N´m (95 ft. lbs.)
(7) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 47). Install the speed sensor
attaching bolt and tighten to a torque of 12 N´m (105
in. lbs.).
(8) 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.).
(9) Install the brake drum onto the rear hub/bear-
ing assembly.
(10) Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 N´m (95 ft. lbs.).
(11) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
TONE WHEEL (REAR AWD)
The rear tone wheel on all wheel drive applications
is an integral part of each rear axle outer C/V joint.
If the rear tone wheel on an all wheel drive vehicle
requires replacement it can not be replace as a sep-
arate component of the rear axle. Tone wheel replace-
ment will require the replacement of the rear axle.
Refer to Differential And Driveline in this service
manual for the rear axle replacement procedure.
Fig. 50 Tone Wheel Removal From Hub/Bearing
Assembly
Fig. 51 Installing Tone Wheel On Hub/Bearing
Assembly
Fig. 52 Correctly Installed Tone Wheel
NSBRAKES 5 - 111
REMOVAL AND INSTALLATION (Continued)