1996 CHRYSLER VOYAGER brake light

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULE............... 2
MAINTENANCE SCHEDULEÐ
DIESEL ENGINE....................... 2SCHEDULEÐA (DIESEL).................. 2
SCHEDULEÐB (DIESEL).................. 3
UNSCHEDULED INSPECTION.............. 2
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Refer to the 1998 GS Service Manual for Gasoline
Engine and non-engine related Maintenance Sched-
ules.
MAINTENANCE SCHEDULEÐDIESEL ENGINE
The following are engine related Maintenance
items which are unique to Diesel engine-equipped
vehicles. Refer to the 1998 GS Service Manual for
Gasoline Engine and non-engine related Maintenance
Schedules.
The service intervals are based on odometer read-
ings in kilometers. There are two maintenance sched-
ules that show proper service intervals. Use the
schedule that best describes the conditions the vehi-
cle is operated under.Schedule-Alists all the sched-
uled maintenance to be performed under normal
operating conditions.Schedule-Bis the schedule for
vehicles that are operated under one or more of the
following conditions:
²Day and night temperatures are below freezing.
²Stop and go driving.
²Long periods of engine idling.
²Driving in dusty conditions.
²Short trips of less than 5 miles.
²Operation at sustained high speeds during hot
weather above 32ÉC (90ÉF).
²Taxi, police or delivery service.
²Trailer towing.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on ScheduleÐA (7,500 miles) or every other
interval shown on ScheduleÐ B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter.
SCHEDULEÐA (DIESEL)
1 000 KM
²Change engine oil.
²Change engine oil filter.
²Check all fluid levels.
²Check correct torque, intake manifold mounting
nuts.
²Check correct torque, exhaust manifold mount-
ing nuts.
²Check correct torque, turbocharger mounting
nuts.
²Check correct torque, water manifold bolts.
10 000 KM
²Change engine oil.
²Change engine oil filter.
20 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
0 - 2 LUBRICATION AND MAINTENANCENS/GS

STEERING KNUCKLE
The front suspension knuckle is not a repairable
component of the vehicles front suspensionIT MUST
BE REPLACED.If bent, broken or damaged in any
way, do not attempt to straighten or repair the steer-
ing knuckle.
Service replacement of the front hub/bearing
assembly can be done with the front steering knuckle
remaining on the vehicle.
LOWER CONTROL ARM
If damaged, the lower control arm casting is ser-
viced only as a complete component. Inspect lower
control arm for signs of damage from contact with
the ground or road debris. If lower control arm shows
any sign of damage, inspect lower control arm for
distortion.Do not attempt to repair or straighten
a broken or bent lower control arm.
The serviceable components of the lower control
arm are: the ball joint assembly, ball joint assembly
grease seal and control arm bushings. Inspect both
control arm bushings for severe deterioration, and
replace if required. Inspect ball joint per inspection
procedure in this section of the service manual and
replace if required. Service procedures to replace
these components are detailed in the specific compo-
nent removal and installation sections in this group
of the service manual.
BALL JOINT (LOWER)
With the weight of the vehicle resting on the road
wheels, grasp the grease fitting as shown in (Fig. 5)
and with no mechanical assistance or added force
attempt to rotate the grease fitting.
If the ball joint is worn the grease fitting will
rotate easily. If movement is noted, replacement of
the ball joint is recommended.
STABILIZER BAR
Inspect for broken or distorted sway bar bushings,
bushing retainers, and worn or damaged sway bar to
strut attaching links. If sway bar to front suspension
cradle bushing replacement is required, bushing can
be removed from sway bar by opening slit and peel-
ing bushing off sway bar.
HUB AND BEARING ASSEMBLY
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
Where axle bearing damage is slight, the noise is
usually not noticeable at speeds above 30 m.p.h..
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.
The threaded holes in the front suspension cradle,
if damaged, can repaired by installing a Heli-Coilt
thread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the suspension crossmember to be repaired,
eliminating the need to replace the crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
Fig. 5 Checking Ball Joint Wear
2 - 12 SUSPENSIONNS
DIAGNOSIS AND TESTING (Continued)

FIXED PROPORTIONING VALVE OPERATION
The fixed proportioning valve is made out of alumi-
num and has an integral mounting bracket. The
fixed proportioning valve is non-serviceable compo-
nent and must be replaced as an assembly if found to
be functioning improperly.
The fixed proportioning valve is mounted to the
bottom of the left rear frame rail, just forward of the
rear shock absorber to frame rail mounting location
(Fig. 6). The proportioning valve has 2 inlet ports for
brake fluid coming from the ABS modulator, and 2
outlet ports for brake fluid going to the rear wheel
brakes.
The fixed proportioning valve operates by allowing
full hydraulic pressure to the rear brakes up to a set
point, called the valve's split point. Beyond this split
point the proportioning valve reduces the amount of
hydraulic pressure to the rear brakes according to a
certain ratio.
Thus, on light brake pedal applications the propor-
tioning valve allows approximately equal brake
hydraulic pressure to be supplied to both the front
and rear brakes. On heavier brake pedal applications
though, the proportioning valve will control hydraulic
pressure to the rear brakes, so that hydraulic pres-
sure at the rear brakes will be lower than that at the
front brakes. This controlled hydraulic pressure to
the rear brakes prevents excessive rear wheel ABS
cycling during moderate stops.
HEIGHT SENSING PROPORTIONING VALVE
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentiallycould result in increased stopping distance of the
vehicle.
On vehicles not equipped with ABS brakes, the
brake systems hydraulic control unit (HCU) is
replaced by a junction block (Fig. 7). The junction
block is made of aluminum and is mounted to the
front suspension crossmember on the drivers side of
the vehicle in the same location as the (HCU) on an
ABS equipped vehicle. The junction block is perma-
nently attached to its mounting bracket and must be
replaced as an assembly with its mounting bracket.
The junction block is used for diagonally splitting the
brake's hydraulic system.
Vehicles not equipped with ABS brakes use a
height sensing proportioning valve. The height sens-
ing proportioning valve is mounted on the left frame
rail at the rear of the vehicle (Fig. 8). The height
sensing proportioning valve uses an actuator assem-
bly (Fig. 8) to attach the proportioning valve to the
left rear spring for sensing changes in vehicle height.
HEIGHT SENSING PROPORTIONING VALVE OPERATION
The height sensing proportioning valve regulates
the hydraulic pressure to the rear brakes. The pro-
portioning valve regulates the pressure by sensing
the load condition of the vehicle through the move-
ment of the proportioning valve actuator assembly
Fig. 6 Fixed Proportioning Valve Location
Fig. 7 Junction Block Location
Fig. 8 Height Sensing Proportioning Valve
5 - 6 BRAKESNS
DESCRIPTION AND OPERATION (Continued)

(Fig. 8). The actuator assembly is mounted between
the height sensing proportioning valve and the actua-
tor bracket on the left rear leaf spring (Fig. 8). As the
rear height of the vehicle changes depending on the
load the vehicle is carrying the height change is
transferred to the height sensing proportioning valve.
This change in vehicle height is transferred through
the movement of the left rear leaf spring. As the posi-
tion of the left rear leaf spring changes this move-
ment is transferred through the actuator bracket
(Fig. 8) to the actuator assembly (Fig. 8) and then to
the proportioning valve.
Thus, the height sensing proportioning valve
allows the brake system to maintain the optimal
front to rear brake balance regardless of the vehicle
load condition. Under a light load condition, hydrau-
lic pressure to the rear brakes is minimized. As the
load condition of the vehicle increases, so does the
hydraulic pressure to the rear brakes.
The proportioning valve section of the valve oper-
ates by transmitting full input hydraulic pressure to
the rear brakes up to a certain point, called the split
point. Beyond the split point the proportioning valve
reduces the amount of hydraulic pressure to the rear
brakes according to a certain ratio. Thus, on light
brake applications, approximately equal hydraulic
pressure will be transmitted to the front and rear
brakes. At heavier brake applications, the hydraulic
pressure transmitted to the rear brakes will be lower
then the front brakes. This will prevent premature
rear wheel lock-up and skid.
The height sensing section of the valve thus
changes the split point of the proportioning valve,
based on the rear suspension height of the vehicle.
When the height of the rear suspension is low, the
proportioning valve interprets this as extra load and
the split point of the proportioning valve is raised to
allow more rear braking. When the height of the rear
suspension is high, the proportioning valve interprets
this as a lightly loaded vehicle and the split point of
the proportioning valve is lowered and rear braking
is reduced.
CHASSIS TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The chassis tubes are steel with a corro-
sion resistant coating applied to the external surfaces
and the flex hoses are made of reinforced rubber. The
rubber flex hoses allow for the movement of the vehi-
cles suspension.
MASTER CYLINDER
The master cylinder (Fig. 9) consists of the follow-
ing components. The body of the master cylinder isan anodized aluminum casting. It has a machined
bore to accept the master cylinder piston and
threaded ports with seats for the hydraulic brake
line connections. The brake fluid reservoir of the
master cylinder assembly is made of a see through
polypropylene type plastic. A low fluid switch is also
part of the reservoir assembly.
This vehicle uses 3 different master cylinders.
Master cylinder usage depends on what type of brake
system the vehicle is equipped with. If a vehicle is
not equipped with antilock brakes, or is equipped
with antilock brakes without traction control, a con-
ventional compensating port master cylinder is used.
If a vehicle is equipped with antilock brakes with
traction control, a dual center port master cylinder is
used.
The third master cylinder used on this vehicle is
unique to vehicles equipped with four wheel disc
brakes. The master cylinder used for this brake
application has a different bore diameter and stroke
then the master cylinder used for the other available
brake applications.
The master cylinders used on front wheel drive
applications (non four wheel disc brake vehicles)
have a master cylinder piston bore diameter of 23.8
mm. The master cylinder used on the all wheel drive
applications (four wheel disc brake vehicles) have a
master cylinder piston bore diameter of 25.4 mm.
When replacing a master cylinder, be sure to
use the correct master cylinder for the type of
brake system the vehicle is equipped with.
The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
Fig. 9 Master Cylinder Assembly
NSBRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)

normal. This may indicate:(1)Abnormal loss of
brake fluid in the master cylinder fluid reservoir
resulting from a leak in the hydraulic system.(2)
Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level sensor closes to ground the
brake warning light circuit. This will turn on the red
brake warning light. At this time, master cylinder
fluid reservoir should be checked and filled to the full
mark with DOT 3 brake fluid.If brake fluid level
has dropped below the add line in the master
cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evi-
dence of a leak.
STOP LAMP SWITCH
The stop lamp switch controls operation of the
vehicles stop lamps. Also, if the vehicle is equippedwith speed control, the stop lamp switch will deacti-
vate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the
right and left tail, stop and turn signal lamp and
CHMSL lamp, by supplying battery current to these
lamps.
The stop lamp switch controls the lamp operation
by opening and closing the electrical circuit to the
stop lamps.
HUB/BEARING REAR WHEEL
The rear hub and bearing assembly used on this
vehicle is serviceable only as a complete assembly. No
attempt should be made to disassemble a rear hub
and bearing assembly in an effort to repair it.
The rear hub and bearing assembly is attached to
the rear axle using 4 mounting bolts that are remov-
able from the back of the rear hub/bearing.
DIAGNOSIS AND TESTING
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
SYMPTOMCHART 1
MISC.
COND.CHART 2
WARNING
LIGHTCHART 3
POWER
BRAKESCHART 4
BRAKE
NOISECHART 5
WHEEL
BRAKES
Brake Warning Light On X NO NO
Excessive Pedal Travel 6 X NO O
Pedal Goes To The Floor 6 X
Stop Light On Without Brakes 3
All Brakes Drag 5
Rear Brakes Drag 2 NO NO
Grabby Brakes O X
Spongy Brake Pedal X NO
Premature Rear Brake Lockup 4 NO NO O
Excessive Pedal Effort 1 O
Rough Engine Idle NO O
Brake Chatter (Rough) NO NO X
Surge During Braking NO NO X
Noise During Braking NO NO X
Rattle Or Clunking Noise NO NO X
Pedal Pulsates During Braking NO NO X
Pull To Right Or Left NO NO X
No: Not A Possible Cause X: Most Likely Cause O: Possible Cause
NSBRAKES 5 - 9
DESCRIPTION AND OPERATION (Continued)

micrometer at a radius approximately 25.4 mm (1
inch) from outer edge of rotor (Fig. 18). If thickness
measurements vary by more than 0.013 mm (0.0005
inch), rotor should be removed and resurfaced, or a
new rotor installed. If cracks or burned spots are evi-
dent, rotor must be replaced.
Light scoring and/or wear is acceptable. If heavy
scoring or warping is evident, the rotor must be
refinished or replaced (See Refinishing/RefacingRotor). If cracks are evident in the rotor, replace the
rotor.
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE TEST
PROCEDURE
On a vehicle equipped with ABS, premature or
excessive rear wheel ABS cycling may be an indica-
tion that the brake fluid pressure to the rear brakes
is above the desired output.
Prior to testing a proportioning valve for function,
check that all tire pressures are correct. Also, ensure
the front and rear brake linings are in satisfactory
condition.It is also necessary to verify that the
brakes shoe assemblies on a vehicle being
tested, are either original equipment manufac-
turers (OEM), or original replacement brake
shoe assemblies meeting the OEM lining mate-
rial specification. The vehicles brake system is
not balanced for after market brake shoe
assembly lining material.
If brake shoe assembly lining material is of satis-
factory condition, and of the correct material specifi-
cation, check for proper proportioning valve function
using the following procedure.
(1) Road test vehicle to be sure the vehicle is truly
exhibiting a condition of excessive rear wheel ABS
cycling. Since ABS cycles both rear brakes together
both proportioning valves of the assembly(Fig.
19) must be tested. Use the following procedure to
test the proportioning valve.
(2) Remove one of the chassis brake lines (Fig. 19)
coming from the ABS modulator, at
(3) the proportioning valve assembly. Remove the
hydraulic brake line going to one of the rear wheels
of the vehicle from the proportioning valve (Fig. 19)
Fig. 17 Minimum Rotor Thickness Markings
Fig. 18 Checking Rotor For Thickness Variation
Fig. 19 Rear Brake Proportioning Valve And Brake
Tube Locations
5 - 16 BRAKESNS
DIAGNOSIS AND TESTING (Continued)

(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)