1996 CHRYSLER VOYAGER brake fluid

MUST always be used when installing brake
hose to caliper.
(12) Bleed the brake system (see Bleeding Brake
System).
WHEEL CYLINDER REAR DRUM BRAKE
DISASSEMBLE
To disassemble the wheel cylinders, proceed as fol-
lows:
(1) Pry boots away from cylinders and remove (Fig.
193).
(2) PressINon one piston to force out opposite
piston, cup and spring (Fig. 193). Then using a soft
tool such as a dowel rod, press out the cup and piston
that remain in the wheel cylinder.
(3) Wash wheel cylinder, pistons, and spring (Fig.
193) in clean brake fluid or alcohol;(DO NOT USE
ANY PETROLEUM BASE SOLVENTS)clean thor-
oughly and blow dry with compressed air. Inspect cyl-
inder bore and piston for scoring and pitting. (Do not
use a rag as lint from the rag will stick to bore sur-
faces.)
(4) Wheel cylinder bores and pistons that are
badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of cor-
rosion, can usually be cleaned with crocus cloth,
using a circular motion. Black stains on the cylinder
walls are caused by piston cups and will not impair
operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the
wheel cylinders, dip them in clean brake fluid. If the
boots are deteriorated, cracked or do not fit tightly on
the pistons or the cylinder casting, install new boots.
(1) Coat cylinder bore with clean brake fluid.
(2) Lightly coat the sealing lip and outer surfaces
of the wheel cylinder cups withonly Mopar Pro-
tect-A-Cup Lubricant p/n 04883068 and no sub-
stitute.
(3) Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with
open end of cups facing each other (Fig. 193).
(4) Install piston in each end of cylinder having
the flat face of each piston contacting the flat face of
each cup, already installed (Fig. 193).
(5) Install a boot over each end of cylinder (Fig.
193).Be careful not to damage boot during
installation.
CLEANING AND INSPECTION
FRONT DISC BRAKE PAD LINING INSPECTION
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the wheel and tire assemblies, and the cali-
pers.
Remove the shoe and lining assemblies. (See Brake
Shoe Removal).
Combined shoe and lining thickness should be
measured at the thinnest part of the brake shoe
assembly.
When a shoe and lining assembly is worn to a
thickness of approximately 7.95 mm (0.313 inch) it
should be replaced.
Replacebothshoe assemblies (inboard and out-
board) on the front wheels. It is also necessary that
bothfront wheel brake shoe assembly sets be
replaced, whenever shoe assemblies on either side of
the vehicle require replacement.
If a shoe assembly does not require replacement,
reinstall it, making sure each shoe assembly is
returned to its original position. (See Brake Shoe
Installation).
REAR DISC BRAKES
BRAKE PAD LINING WEAR
If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the wheel and tire assemblies, and the cali-
pers.
Remove the rear disc brake shoes. Refer to Rear
Disc Brake Shoe Removal in the Removal And Instal-
Fig. 192 Installing Dust Boot In Caliper Counterbore
5 - 76 BRAKESNS
DISASSEMBLY AND ASSEMBLY (Continued)

lation section in this group of the service manual for
the required procedure.
The combined brake shoe and lining material
thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total
thickness of approximately 7.0 mm (9/32 inch) they
should be replaced.
Replacebothbrake shoe assemblies (inboard and
outboard). It is necessary thatbothrear wheel sets
be replaced whenever brake shoe assemblies on
either side are replaced.
If the brake shoe assemblies do not require
replacement, reinstall, the assemblies making sure
each brake shoe is returned to the original position.
Refer to Rear Disc Brake Shoe Installation in the
Removal And Installation section in this group of the
service manual for the required procedure.
CALIPER INSPECTION
Check for brake fluid leaks in and around boot
area and inboard lining, and for any ruptures, brit-
tleness or damage to the piston dust boot. If the boot
is damaged, or a fluid leak is visible, disassemble cal-
iper assembly and install a new seal and boot, and
piston if scored. Refer to Rear Disc Brake Caliper in
the Disassembly And Assembly Section in this group
of the service manual.
Check the guide pin dust boots to determine if they
are in good condition. Replace if they are damaged,
dry, or found to be brittle. Refer to Rear Disc Brake
Caliper in the Disassembly And Assembly Section in
this group of the service manual.
REAR DRUM BRAKE SHOE LINING INSPECTION
(1) Remove the tire and wheel assembly from the
vehicle
(2) Remove the rear brake adjusting hole cover
plug (Fig. 194).
(3) Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the
notches on the adjusting screw star wheel.
(4) Insert Tool C-3784 into brake adjusting hole
and engage notches of brake adjusting screw star
wheel. Release brake by prying down with adjusting
tool.
(5) Remove the rear brake drum from the rear
hub/bearing assembly.
(6) Inspect brake lining for wear, shoe alignment,
and or contamination from grease or brake fluid.
Fig. 193 Rear Wheel Cylinder (Exploded View)
Fig. 194 Brake Adjustment Hole Rubber Plug
NSBRAKES 5 - 77
CLEANING AND INSPECTION (Continued)

REAR DRUM BRAKE WHEEL CYLINDER
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
BRAKE HOSE AND BRAKE LINES INSPECTION
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference.
The steel brake tubing should be inspected period-
ically for evidence of physical damage or contact with
moving or hot components.
The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections and the chassis brake tubes between the
hydraulic control unit and the proportioning valve
must also be inspected. This flexible tubing must be
inspected for kinks, fraying and its contact with
other components of the vehicle or contact with the
body of the vehicle.
REAR WHEEL HUB AND BEARING ASSEMBLY
The rear hub and bearing assembly is designed for
the life of the vehicle and should require no mainte-
nance. The following procedure may be used for eval-
uation of bearing condition.
With wheel and brake drum removed, rotate
flanged outer ring of hub. Excessive roughness, lat-
eral play or resistance to rotation may indicate dirt
intrusion or bearing failure. If the rear wheel bear-
ings exhibit these conditions during inspection, the
hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive
grease loss may also require bearing replacement.
Moderate grease loss from bearing is considered nor-
mal and should not require replacement of the hub
and bearing assembly.
ADJUSTMENTS
STOP LAMP SWITCH
(1) Remove stop lamp switch from its bracket by
rotating it approximately 30É in a counter-clockwise
direction.
(2) Disconnect wiring harness connector from stop
lamp switch.
(3) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(4) Install the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp
switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting
bracket. When switch is fully installed in the square
hole of the bracket, rotate switch clockwise approxi-
mately 30É to lock the switch into the bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If too much force is used, damage to the vacuum
booster, stop lamp switch or striker (Fig. 195) can
result.
(5) Connect the wiring harness connector to the
stop lamp switch.
(6) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger
(Fig. 195) to ratchet backward to the correct position.
Fig. 195 Stop Light Switch Location In Vehicle
5 - 78 BRAKESNS
CLEANING AND INSPECTION (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)

ANTILOCK BRAKE SYSTEM ± TEVES MARK-20
INDEX
page page
DESCRIPTION AND OPERATION
ABS BRAKE SYSTEM COMPONENTS........ 87
ABS BRAKES COMPONENT
ABBREVIATION LIST.................... 85
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE....................... 86
ABS FUSES............................ 89
ABS MASTER CYLINDER AND POWER
BRAKE BOOSTER..................... 87
ABS RELAYS........................... 89
ABS WARNING LAMP (YELLOW)............ 91
ANTILOCK BRAKES OPERATION
DESCRIPTION........................ 85
ASR VALVE (ABS WITH TRACTION
CONTROL ONLY)...................... 88
CONTROLLER ANTILOCK BRAKES (CAB)..... 90
HCU BRAKE FLUID ACCUMULATORS AND
NOISE DAMPING CHAMBER............. 88
HCU PUMP/MOTOR..................... 89
HYDRAULIC CIRCUITS AND VALVE
OPERATION.......................... 92
INLET VALVES AND SOLENOIDS............ 88
INTEGRATED CONTROL UNIT (ICU)......... 87
OUTLET VALVES AND SOLENOIDS.......... 88
PROPORTIONING VALVES................ 89
WHEEL SPEED SENSORS................. 89
DIAGNOSIS AND TESTING
ABS BRAKE DIAGNOSTIC TOOL
CONNECTOR......................... 96
ABS DIAGNOSTIC TROUBLE CODES........ 97
ABS DIAGNOSTICS MANUAL.............. 96ABS GENERAL DIAGNOSTICS
INFORMATION........................ 95
ABS SERVICE PRECAUTIONS.............. 99
ABS SYSTEM SELF DIAGNOSTICS.......... 96
ABS WIRING DIAGRAM INFORMATION....... 95
BRAKE FLUID CONTAMINATION............ 98
DRB DIAGNOSTIC SCAN TOOL USAGE...... 96
INTERMITTENT DIAGNOSTIC TROUBLE
CODES.............................. 97
PROPORTIONING VALVE................. 98
TEST DRIVING ABS COMPLAINT VEHICLE.... 98
TONEWHEEL INSPECTION................ 98
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM............................. 99
BRAKE FLUID LEVEL INSPECTION.......... 99
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS.... 100
CONTROLLER ANTILOCK BRAKES (CAB).... 103
HYDRAULIC CONTROL UNIT.............. 100
TONE WHEEL (REAR AWD)............... 111
TONE WHEEL (REAR FWD)............... 110
WHEEL SPEED SENSOR (FRONT)......... 105
WHEEL SPEED SENSOR (REAR AWD)...... 108
WHEEL SPEED SENSOR (REAR FWD)...... 106
SPECIFICATIONS
BRAKE FASTENER TORQUE
SPECIFICATIONS..................... 112
SPEED SENSOR TONE WHEEL RUNOUT.... 112
WHEEL SPEED SENSOR TO TONE
WHEEL CLEARANCE.................. 112
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Antilock Brake System (ABS) is to
prevent wheel lock-up under braking conditions on virtu-
ally any type of road surface. Antilock Braking is desirable
because a vehicle which is stopped without locking the
wheels will retain directional stability and some steering
capability. This allows the driver to retain greater control
of the vehicle during braking.
This section of the service manual covers the description
and on car service for the ITT Teves Mark 20 ABS Brake
System and the ITT Teves Mark 20 ABS Brake System
with Traction Control. If other service is required on the
non ABS related components of the brake system, refer to
the appropriate section in this group of the service manual
for the specific service procedure required.
ABS BRAKES COMPONENT ABBREVIATION LIST
In this section of the service manual, several
abbreviations are used for the components of the
Teves Mark 20 ABS Brake System and the Teves
Mark 20 ABS Brake System with Traction Control.
They are listed below for your reference.
²CAB±Controller Antilock Brake
²ICU±Integrated Control Unit
²HCU±Hydraulic Control Unit
²TCS±Traction Control
²ABS±Antilock Brake System
²PSI±Pounds Per Square Inch (pressure)
²WSS±Wheel Speed Sensor
²FWD±Front Wheel Drive
²AWD±All Wheel Drive
²DTC±Diagnostic Trouble Code
NSBRAKES 5 - 85

ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE
This ABS System represents the current state-of-
the-art in vehicle braking systems and offers the
driver increased safety and control during braking.
This is accomplished by a sophisticated system of
electrical and hydraulic components. As a result,
there are a few performance characteristics that may
at first seem different but should be considered nor-
mal. These characteristics are discussed below.
NORMAL BRAKING SYSTEM FUNCTION
Under normal braking conditions, the ABS System
functions the same as a standard brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS SYSTEM OPERATION
If a wheel locking tendency is detected during a
brake application, the brake system will enter the
ABS mode. During ABS braking, hydraulic pressure
in the four wheel circuits is modulated to prevent
any wheel from locking. Each wheel circuit is
designed with a set of electric solenoids to allow mod-
ulation, although for vehicle stability, both rear
wheel solenoids receive the same electrical signal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into four control channels.
During antilock operation of the vehicle's brake sys-
tem the front wheels are controlled independently
and are on two separate control channels and the
rear wheels of the vehicle are controlled together.
The system can build and release pressure at each
wheel, depending on signals generated by the wheel
speed sensors (WSS) at each wheel and received at
the Controller Antilock Brake (CAB).
ABS operation is available at all vehicle speeds
above 3 to 5 mph. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
VEHICLE HANDLING PERFORMANCE DURING
ABS BRAKING
It is important to remember that an antilock brake
system does not shorten a vehicle's stopping distance
under all driving conditions, but does provide
improved control of the vehicle while stopping. Vehi-
cle stopping distance is still dependent on vehicle
speed, weight, tires, road surfaces and other factors.
Though ABS provides the driver with some steer-
ing control during hard braking, there are conditions
however, where the system does not provide any ben-
efit. In particular, hydroplaning is still possible when
the tires ride on a film of water. This results in the
vehicles tires leaving the road surface rendering the
vehicle virtually uncontrollable. In addition, extremesteering maneuvers at high speed or high speed cor-
nering beyond the limits of tire adhesion to the road
surface may cause vehicle skidding, independent of
vehicle braking. For this reason, the ABS system is
termed Antilock instead of Anti-Skid.
NOISE AND BRAKE PEDAL FEEL
During ABS braking, some brake pedal movement
may be felt. In addition, ABS braking will create
ticking, popping and/or groaning noises heard by the
driver. This is normal due to pressurized fluid being
transferred between the master cylinder and the
brakes. If ABS operation occurs during hard braking,
some pulsation may be felt in the vehicle body due to
fore and aft movement of the suspension as brake
pressures are modulated.
At the end of an ABS stop, ABS will be turned off
when the vehicle is slowed to a speed of 3±4 mph.
There may be a slight brake pedal drop anytime that
the ABS is deactivated, such as at the end of the stop
when the vehicle speed is less then 3 mph or during
an ABS stop where ABS is no longer required. These
conditions will exist when a vehicle is being stopped
on a road surface with patches of ice, loose gravel or
sand on it. Also stopping a vehicle on a bumpy road
surface will activate ABS because of the wheel hop
caused by the bumps.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
lock-up, some wheel slip is desired in order to
achieve optimum braking performance. Wheel slip is
defined as follows, 0 percent slip means the wheel is
rolling freely and 100 percent slip means the wheel is
fully locked. During brake pressure modulation,
wheel slip is allowed to reach up to 25 to30%. This
means that the wheel rolling velocity is 25 to 30%
less than that of a free rolling wheel at a given vehi-
cle speed. This slip may result in some tire chirping,
depending on the road surface. This sound should not
be interpreted as total wheel lock-up.
Complete wheel lock up normally leaves black tire
marks on dry pavement. The ABS System will not
leave dark black tire marks since the wheel never
reaches a fully locked condition. Tire marks may
however be noticeable as light patched marks.
START UP CYCLE
When the ignition is turned on, a popping sound
and a slight brake pedal movement may be noticed.
Additionally, when the vehicle is first driven off a
humming may be heard and/or felt by the driver at
approximately 20 to 40 kph (12 to 25 mph). The ABS
warning lamp will also be on for up to 5 seconds
after the ignition is turned on. All of these conditions
are a normal function of ABS as the system is per-
forming a diagnosis check.
5 - 86 BRAKESNS
DESCRIPTION AND OPERATION (Continued)

PREMATURE ABS CYCLING
NOTE: When working on a vehicle which has a
complaint of premature ABS cycling it may be nec-
essary to use a DRB Scan Tool to detect and verify
the condition.
There is one complaint called Premature ABS
Cycling in which neither the Red Brake Warning
Lamp nor the Amber Antilock Lamp were illumi-
nated and no fault codes were stored in the CAB.
Symptoms of Premature ABS Cycling, include click-
ing sounds from the solenoids valves, pump motor
running and pulsations in the brake pedal. This con-
dition can occur at any braking rate of the vehicle
and on any type of road surface. This creates an
additional condition which needs to be correctly
assessed when diagnosing problems with the antilock
brake system.
The following conditions are common causes that
need to be checked when diagnosing a condition of
Premature ABS Cycling. Damaged tone wheels,
incorrect tone wheels, damage to a wheel speed sen-
sor mounting boss on a steering knuckle, a loose
wheel speed sensor mounting bolt, and excessive tone
wheel runout. Also, an excessively large tone wheel
to wheel speed sensor air gap can lead to the condi-
tion of Premature ABS Cycling. Special attention is
to be given to these components when diagnosing a
vehicle exhibiting the condition of Premature ABS
Cycling. After diagnosing the defective component,
repair or replace as required.
When the component repair or replacement is com-
pleted, test drive the vehicle to verify the condition of
Premature ABS Cycling has been corrected.
ABS BRAKE SYSTEM COMPONENTS
The following is a detailed description of the Teves
Mark 20 ABS brake system components. For infor-
mation on servicing the base brake system compo-
nents, see the base Brake System section of this
Service Manual.
ABS MASTER CYLINDER AND POWER BRAKE
BOOSTER
A vehicle equipped with Teves Mark 20 ABS
without optional traction control uses the same
type of a master cylinder and power brake
booster (Fig. 1) as a vehicle not equipped with
antilock brakes.
A vehicle equipped with Teves Mark 20 ABS
with Traction control uses a unique center port
master cylinder. If the master cylinder is
replaced on a vehicle equipped with traction
control be sure the right type of master cylin-
der is installed.A vehicle equipped with four wheel disc
brakes (AWD applications) also have a unique
master cylinder. The master cylinder used on
these vehicles have a piston bore diameter
which is larger then the master cylinder used
on the other brake applications.
The primary and secondary outlet ports on the
master cylinder go directly to the hydraulic control
unit HCU.
Reference the appropriate section of this service
manual for further information on the individual
components.
INTEGRATED CONTROL UNIT (ICU)
The hydraulic control unit (HCU) (Fig. 2) used
with the Teves Mark 20 ABS is different from the
HCU used on previous Chrysler products with ABS.
The HCU used on this ABS system is part of the
integrated contol unit (ICU). The HCU is part of
what is referred to as the ICU because the HCU and
the controller antilock brakes (CAB) are combined
(integrated) into one unit. This differs from previous
Chrysler products with ABS, where the HCU and the
CAB were separate components located in different
areas of the vehicle.
Teves Mark 20 ABS uses two different HCU's and
CAB's depending on the type of ABS system the vehi-
cle is equipped with. There is a unique HCU and
CAB for a vehicle equipped with just ABS and a
unique HCU and CAB for a vehicle equipped with
ABS and traction control.
NOTE: The HCU and CAB used on a vehicle that is
equipped with only ABS and on a vehicle that is
equipped with ABS and traction control are differ-
ent. The HCU on a vehicle equipped with ABS and
traction control has a valve block housing (Fig. 2)
that is approximately 1 inch longer on the low pres-
sure fluid accumulators side than a HCU for a vehi-
cle that is equipped with only ABS.
Fig. 1 Master Cylinder And Vacuum Booster
NSBRAKES 5 - 87
DESCRIPTION AND OPERATION (Continued)