1996 CHRYSLER VOYAGER torque

(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)

SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
The total indicator runout allowed for both the
front and rear tone wheel measured using a dial indi-
cator is 0.15 mm (.006 in.).
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE
FRONT WHEEL
Minimum Clearance .35mm (.014 in.)
Maxamum Clearance 1.2 mm (.047 in.)
REAR WHEEL
Minimum Clearance .40mm (.016 in.)
Maxamum Clearance 1.2 mm (.047 in.)
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.)DESCRIPTION TORQUE
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.)
5 - 112 BRAKESNS

BRAKES
CONTENTS
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION........................ 1
DESCRIPTION AND OPERATION
MASTER CYLINDER..................... 1
DIAGNOSIS AND TESTING
MASTER CYLINDER FLUID LEVEL CHECK . . . 2REAR DRUM BRAKE ADJUSTMENT........ 1
REMOVAL AND INSTALLATION
BRAKE PEDAL TORQUE SHAFT ASSEMBLY . . 4
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES........ 2
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle contains
the same components as brake systems described in
group 5 of the service manual, with the exception of
the brake pedal system and master cylinder. These
differences are mainly related to service procedures.
The major differences are as follows:
²Use of a torque shaft assembly to transfer brake
pedal travel to the power brake booster and master
cylinder on the left side of the vehicle
²A unique power brake booster and master cylin-
der.
Refer to the Base Brake System Component
Description in the General Information section of
group 5 for more information on components used in
the base brake system.
DESCRIPTION AND OPERATION
MASTER CYLINDER
The master cylinder used on this vehicle functions
the same as master cylinders used in other brake
systems. Refer to the Master Cylinder in the Descrip-
tion and Operation section of group 5 for more infor-
mation.
DIAGNOSIS AND TESTING
REAR DRUM BRAKE ADJUSTMENT
The rear drum brakes on front wheel drive vehicles
automatically adjust, when required, during the nor-
mal operation of the vehicle every time the brakes
are applied. Use the following procedure to test the
operation of the automatic adjuster.
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the adjustment slot in each brake support
plate to provide visual access of brake adjuster star
wheel. Disconnect parking brake cable from one side
of the vehicle at the equalizer under the vehicle at
the left frame rail. Working on the side of the vehicle
that parking brake cable is connected to, hold the
adjuster lever off the star wheel with a suitable tool,
and loosen the star wheel approximately 30 notches
in relation to the adjuster lever. This is to eliminate
the possibility that the brake is already properly
adjusted. Reconnect the parking brake cable and
repeat the procedure for the other side of the vehicle.
Fig. 1 Master Cylinder Assembly
NS/GSBRAKES 5 - 1

BRAKE PEDAL TORQUE SHAFT ASSEMBLY
REMOVE
(1) Disconnect Brake Pedal Switch Electrical Con-
nector
(2) Loosen the six (6) retaining nuts from the
Brake Pedal Bracket. Do not remove nuts from studs.
(Fig. 6)
(3) Remove steering column intermediate shaft.
Loosen 72 and 36 way electrical connector brackets.
Move components out of the way of the brake pedal
bracket.
(4) Access the brake booster bracket inside the
passenger compartment. Remove the retaining clip
from brake pedal torque shaft.Discard retaining
clip. It is not to be re-used. Replace only with a
new clip when reassembled.(Fig. 7)(5) Loosen the retaining nut (1) from the Brake
Booster Bracket in the engine compartment. Do not
remove nut from stud. Loosen the four Brake Booster
retaining nuts from inside the passenger compart-
ment. Do not remove nuts from stud (Fig. 6)
(6) The pedal arm, link and pedal bracket can be
disconnected from the torque shaft to make it easier
to remove.
(7) Remove torque shaft from vehicle
INSTALL
(1) Install torque shaft. Reconnect pedal arm, link
and pedal bracket assembly to torque shaft as neces-
sary.
(2) Tighten the retaining nut (1) for the Brake
Booster Bracket in the engine compartment. Tighten
the four (4) Brake Booster retaining nuts from inside
the passenger compartment.
(3) Install new retaining clip on torque shaft.
(4) Install steering column intermediate shaft.
Install 72 and 36 way connector brackets.
(5) Tighten the six (6) retaining nuts for the Brake
Pedal Bracket assembly.
(6) Connect the Brake Pedal Switch connector.
Fig. 6 Torque Shaft and Brake Pedal Assembly
Fig. 7 Brake Vacuum Booster Bracket
5 - 4 BRAKESNS/GS
REMOVAL AND INSTALLATION (Continued)

SERVICE DIAGNOSIS±IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINESClutch disc hub splines damaged during
installationClean, smooth, and lubricate disc and
shaft splines. Replace clutch assembly
and/or input shaft if splines are severely
damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on splines
of input shaft and discClean input shaft splines and disc
splines, then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATEOccurs in vehicles stored or not driven
for extended period of time. Also occurs
after steam cleaning if vehicle is not
used for extended period.Replace clutch assembly
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace clutch assembly
Clutch cover diaphragm spring damaged
during transaxle installationReplace clutch assembly
Release fork and (or) bushings
damagedReplace fork and (or) bushings if worn or
damaged
Clutch cable binding or routed
incorrectlyCheck and correct cable routing
Self-adjuster in cable not functioning
properly, resulting in excess cable slackPull on cable conduit at transaxle (as if
disconnecting cable) to check adjuster
operation
Clutch pedal travel restricted Verify clutch pedal can travel all the way
to the downstop on the bracket
SERVICE DIAGNOSIS±CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL MAKES
REPEATED9POP9NOISE
IN THE FIRST INCH OF
TRAVELSelf-adjusting mechanism in cable
defective (LHD Applications)Replace clutch cable (LHD Applications)
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOORPedal bushings worn out or inadequate
lubricationReplace or lubricate bushings
Clutch pedal assist spring fittings worn
outReplace assist spring fittings
Clutch release shaft bushings in the
bellhousing are worn outReplace release shaft and bushings
DRIVE PLATE MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft boltsClean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
NS/GSCLUTCH 6 - 7
DIAGNOSIS AND TESTING (Continued)

ADJUSTMENTS
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear. This adjuster mechanism is located
within the clutch cable assembly. The preload spring
maintains tension on the cable. This tension keeps
the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
ADJUSTER MECHANISM FUNCTION CHECK Ð
LHD
(1) With slight pressure, pull the clutch release
lever end of the cable to draw the cable taut. Push
the clutch cable housing toward the dash panel (With
less than 20 lbs. of effort, the cable housing should
move 30-50mm.). This indicates proper adjuster
mechanism function. If the cable does not adjust,
determine if the mechanism is properly seated on the
bracket.
(2) If the adjust mechanism functions properly,
route cable to the transaxle.
(3) Insert cable into transaxle and through clutch
release lever. Ensure the cable is routed through the
smaller hole in the transaxle deck (Fig. 10).
(4) Pull down on cable and insert cable retaining
clip onto clutch cable end.
(5) Check clutch pedal position switch operation.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position.
SPECIFICATIONS
CLUTCH TIGHTENING REFERENCE
2.0/2.4 LITER GASOLINE ENGINE
DESCRIPTION TORQUE
Drive Plate Bolts............95N´m(70ft.lbs.)
Lower Trans. Cover.........12N´m(105 in. lbs.)
Modular Clutch Bolts.........74N´m(55ft.lbs.)
Upper Trans. Cover.........12N´m(105 in. lbs.)
2.5 LITER DIESEL ENGINE
DESCRIPTION TORQUE
Flywheel Bolts..............95N´m(70ft.lbs.)
Lower Trans. Cover.........12N´m(105 in. lbs.)
Clutch Pressure Plate Bolts....27N´m(20ft.lbs.)
Upper Trans. Cover.........12N´m(105 in. lbs.)
6 - 16 CLUTCHNS/GS

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS................ 1
AUTOMATIC TRANSMISSION OIL COOLERÐ
2.4L................................. 3
COOLANT RECOVERY SYSTEM (CRS)....... 3
COOLANT.............................. 3
COOLING SYSTEM....................... 2
ENGINE BLOCK HEATER.................. 5
ENGINE THERMOSTAT.................... 3
RADIATOR PRESSURE CAP................ 4
RADIATOR............................. 3
WATER PUMPS......................... 3
DESCRIPTION AND OPERATION
COOLANT PERFORMANCE................. 6
RADIATOR HOSES AND CLAMPS........... 6
WATER PIPESÐ3.0L ENGINE.............. 6
WATER PUMPÐ3.3/3.8L ENGINES.......... 7
WATER PUMPÐ2.4L ENGINE.............. 6
WATER PUMPÐ3.0L ENGINE.............. 6
DIAGNOSIS AND TESTING
ACCESSORY DRIVE BELT.................. 7
COOLING SYSTEM DIAGNOSIS............. 8
DEAERATION.......................... 16
ELECTRIC FAN MOTOR TEST.............. 14
LOW COOLANT LEVEL AERATION.......... 15
PRESSURE TESTING RADIATOR CAP....... 15
RADIATOR CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK.............. 15
RADIATOR COOLANT FLOW TEST.......... 14
RADIATOR FAN CONTROL................ 14
TEMPERATURE GAUGE INDICATION........ 16
TESTING COOLING SYSTEM FOR LEAKS.... 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE........ 16
COOLANT LEVEL SERVICE................ 16COOLANTÐADDING ADDITIONAL.......... 16
COOLING SYSTEMÐDRAINING............ 16
COOLING SYSTEMÐREFILLING........... 16
REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELTSÐ2.4L.......... 23
ACCESSORY DRIVE BELTSÐ3.0L.......... 24
ACCESSORY DRIVE BELTÐ3.3/3.8L........ 24
ENGINE BLOCK HEATER................. 23
FAN MODULE.......................... 22
RADIATOR DRAINCOCK.................. 21
RADIATOR............................ 21
THERMOSTATÐ2.4L ENGINE............. 19
THERMOSTATÐ3.0L ENGINE............. 20
THERMOSTATÐ3.3/3.8L ENGINES......... 20
WATER PUMP INLET TUBEÐ2.4L ENGINE . . . 17
WATER PUMPÐ3.3/3.8L ENGINES......... 19
WATER PUMPÐ2.4L ENGINE............ 17
WATER PUMPÐ3.0L ENGINE............. 18
CLEANING AND INSPECTION
ACCESSORY DRIVE BELT................. 25
CHEMICAL CLEANING................... 25
COOLING SYSTEM CLEANING............. 25
RADIATOR PRESSURE CAP............... 25
REVERSE FLUSHING THE ENGINE......... 25
REVERSE FLUSHING THE RADIATOR....... 25
WATER PUMP......................... 24
ADJUSTMENTS
BELT TENSION CHART................... 26
BELT TENSION GAUGE METHOD........... 26
PROPER BELT TENSION................. 25
SPECIFICATIONS
COOLING SYSTEM CAPACITY............. 26
TORQUE CHART........................ 26
SPECIAL TOOLS
COOLING............................. 26
GENERAL INFORMATION
ACCESSORY DRIVE BELTS
The accessory drive system utilizes two different
style of drive belts. The conventional V-belt and the
Poly-V belt are used to drive the generator, air con-
ditioning compressor, power steering pump and waterpump. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
Belt tensioning should be performed with the aid of a
Burroughs gauge Special Tool C-4162. Because of
space limitations in the engine compartment, the use
of the gauge may be restricted. Raise the vehicle on a
hoist and then remove the splash shield to gain
access to the drive belts.
NSCOOLING SYSTEM 7 - 1