2001 CHRYSLER VOYAGER ABS

SPECIFICATIONS
SPECIFICATIONS - REAR DRIVELINE MODULE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Driveline Module-to-Body 54 40 Ð
Bolt, Halfshaft-to-Ouput Flange 61 45 Ð
Bolt, Overrunning Clutch Housing-to-
Differential60 44 Ð
Bolt, Torque Arm-to-Differential Assembly 60 44 Ð
Bolt, Torque Arm Mount-to-Body 54 40 Ð
Nut, Input Flange 135 100 Ð
Plug, Differential Drain/Fill 35 26 Ð
Plug, Overrunning Clutch Housing Drain/Fill 30 22 Ð
Vent, Differential/Overrunning Clutch
Housing12 Ð 110
SPECIAL TOOLS
SPECIAL TOOLS
BI-DIRECTIONAL
OVERRUNNING CLUTCH
DESCRIPTION
The bi-directional overrunning clutch (BOC) (Fig.
28) works as a mechanical disconnect between the
front and rear axles, preventing torque from being
transferred from the rear axle to the front. The BOC
is a simply an overrunning clutch which works in
both clockwise and counter-clockwise rotations. This
means that when the output (the rear axle) is rotat-
ing faster in one direction than the input (front axle),
there is no torque transmission. But when the input
speed is equal to the output speed, the unit becomes
locked. The BOC provides significant benefits regard-
ing braking stability, handling, and driveline durabil-
ity. Disconnecting the front and the rear driveline
during braking helps to maintain the braking stabil-
ity of an AWD vehicle. In an ABS/braking event, the
locking of the rear wheels must be avoided for stabil-
ity reasons. Therefore brake systems are designed to
Tool 6958
Tool 8493
Tool 8802
RSREAR DRIVELINE MODULE3-37
REAR DRIVELINE MODULE (Continued)

lock the front wheels first. Any torque transfer from
the rear axle to the front axle disturbs the ABS/brak-
ing system and causes potential instabilities on a
slippery surface. The BOC de-couples the rear driv-
eline as soon the rear wheels begin to spin faster
than the front wheels (front wheels locked) in order
to provide increased braking stability. Furthermore
the BOC also reduces the likelihood of throttle off
over-steer during cornering. In a throttle off maneu-
ver, the BOC once again de-couples the rear driveline
forcing all the engine brake torque to the front
wheels. This eliminates the chance of lateral slip on
the rear axle and increases it on the front. The vehi-
cle will therefore tend to understeer, a situation
which is considered easier to manage in most circum-
stances. During this maneuver, and during the ABS
braking event, the BOC does not transmit torque
through to the rear wheels. The rear driveline mod-
ule, with the BOC, will perform the same as a front
wheel drive vehicle during these events. The gear
ratio offset between the front and rear differentials
force the BOC into the overrunning mode most of the
time. This allows BOC to significantly reduce the
rolling resistance of the vehicle, which improves fuel
consumption, allows the downsizing of the driveline
components, and prevents the PTU and propshaft
joints from overheating.
OPERATION
In order to achieve all-wheel drive operation in
reverse, the overrunning clutch locking functional
direction must be reversible. The bi-directional over-
running clutch (BOC) changes the operational mode
direction depending on the propeller shaft direction.
The propeller shaft rotates in the clockwise (when
viewed from the front) direction when the vehicle is
moving forward, which indexes the BOC to the for-
ward overrunning position. When the vehicle is in
reverse, the propeller shaft will rotate counter-clock-
wise and index the BOC to the reverse overrunning
position.
The BOC acts as a mechanical stator. It is active
(transmitting torque), or it is not active and in over-
running mode (not transmitting torque). This ªall or
nothingº approach to torque transfer would cause a
sudden application of all available power to the rear
wheels, which is not desirable. Therefore it is run in
series with a viscous coupler to smooth, dampen, and
limit the transmission of torque to the rear axle and
to prevent a step style torque input to the rear axle.
STEADY STATE, LOW TO MODERATE SPEED, NO
FRONT WHEEL SLIP, FORWARD DIRECTION
During normal driving conditions, (no wheel slip),
the inner shaft (front axle) and outer race (viscous
coupler) are running at different speeds due to the
different gear ratios between the front and rear dif-
ferentials. In this condition, the outer race is always
spinning faster (overdriving between 5-32 rpm) than
the inner shaft. When the BOC (Fig. 29) is running
under these conditions, at low vehicle speeds the
drag shoes and the cage keep the rollers up on the
left side (forward side) of the inner shaft flats. This is
what is known as ªoverrunning mode.º Notice that
when the clutch is in overrunning mode, the rollers
are spinning clockwise and with the outer race, thus
no torque is being transferred.
NOTE: Low speed, forward and reverse operation is
identical, just in opposite directions. (Fig. 29)
shows forward direction in reverse the rollers are
on the other side of the flats due to a reversal of
the cage force.
TRANSIENT CONDITION (BOC LOCKED), FRONT
WHEEL SLIP, FORWARD DIRECTION
When the front wheels lose traction and begin to
slip, the propeller shaft and rear axle pinion speed
difference decreases to zero. At this point the input
shaft (cam) becomes the driving member of the BOC
(Fig. 30), compressing the rollers against the outer
race. This locks the input shaft with the outer race
and transmits torque to the housing of the viscous
coupler, that in turn transmits torque to the rear
axle pinion. It should also be noted that when the
device is locked, the inner shaft and the outer race
are rotating at the same speed. The rollers are
pinched at this point and will stay locked until a
torque reversal (no front wheel slip) occurs. When
locked, the viscous coupler slips during the torque
transfer and the amount of torque transferred is
dependent on the coupling characteristic and the
amount of front wheel slip.
3 - 38 REAR DRIVELINE MODULERS
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)

To keep the rollers in the overrunning position and
avoid undesired9high speed lockup9, a high speed
latch (Fig. 33) positions the cage before the ground
shoes lift off. A further explanation of the high speed
effects follows as well. Utilizing only the friction
shoes approach means that at high speed the
required ground shoe drag torque would cause exces-
sive brake shoe wear or the roller will begin to
migrate to the opposite side of the flat due to the
drag force of the outer race. This would result in sys-
tem lock-up. (Fig. 34) shows the BOC as it crosses
the speed where the brake shoe force is overcome by
the roller drag on the outer race. Notice that the
roller is locking up on the opposite side of the flat
and the cage supplies no force on the rollers.
This lock-up is not desired, and requires the use of
another mechanism to prevent the lock-up. The
device that prevents undesired high-speed lock-up is
called a9high speed latch9.
Similar to the friction shoes, the two-piece high-
speed latch will separate from each other at high
rotational speeds due to centrifugal effects. (Fig. 35)
shows the high speed latch engaged. The gap9x9
increases with speed, eventually locking into one of
the slots in the BOC shaft. When the high-speed
latch is activated (propeller shaft speed reaches X
amount), the cage is partially fixed, and cannot lock
on the wrong side of the flat as shown (Fig. 34). Thehigh speed latch is a one way device and does not
prevent high-speed lockup in the reverse direction. At
high speeds, the BOC provides the same function as
low speeds, transferring torque to the viscous coupler
only when front wheel slip overcomes the axle ratio
offset.
At high speed, the rollers are forced outward to the
outer race because of centrifugal force. At high
speeds, the friction shoes can no longer prevent lock-
up. When the teeth on the high-speed latch engage
into the input shaft, it keeps the rollers centered
above the flats because the tabs on the latch are
locked into the cage. (Fig. 36) shows the roller config-
uration with the High-Speed Latch engaged.
On the BOC shaft, the high speed latch teeth lock
up in the grooved areas, shown in (Fig. 37), when the
turning speed reaches the critical value. (Fig. 37)
also shows the outer race/viscous coupler. Notice the
surface (outer race) the rollers mate against when
transferring torque.
Fig. 32 Location of the Grounding Element
1 - DIFFERENTIAL HOUSING
2 - GROUND TAB
3 - GARTER SPRING
Fig. 33 BOC High Speed Latch (Not Engaged)
1 - TOOTH (TWO PLACES)
2 - GARTER SPRING
3 - TABS AT BOTH ENDS FIT INTO SLOTS IN CAGE
4 - TWO PART DESIGN
RSREAR DRIVELINE MODULE3-41
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 67
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION............................2
OPERATION.............................2
WARNING...............................3
CAUTION................................3
DIAGNOSIS AND TESTING..................3
BASE BRAKE SYSTEM...................3
STANDARD PROCEDURE...................6
BASE BRAKE BLEEDING..................6
SPECIFICATIONS.........................8
SPECIAL TOOLS..........................8
BRAKE FLUID LEVEL SWITCH
DESCRIPTION............................9
OPERATION.............................9
REMOVAL...............................9
INSTALLATION............................9
HYDRAULIC/MECHANICAL
DESCRIPTION...........................10
OPERATION.............................12
DIAGNOSIS AND TESTING.................12
DRUM BRAKE AUTOMATIC ADJUSTER......12
BRAKE LINES
DESCRIPTION...........................13
OPERATION.............................13
INSPECTION............................13
BRAKE PADS/SHOES - FRONT
REMOVAL..............................13
CLEANING..............................14
INSPECTION............................14
INSTALLATION...........................15
BRAKE PADS/SHOES - REAR DISC
REMOVAL..............................15
CLEANING..............................17
INSPECTION............................17
INSTALLATION...........................17
BRAKE PADS/SHOES - REAR DRUM
REMOVAL..............................18INSPECTION............................20
INSTALLATION...........................21
ADJUSTMENTS..........................22
DISC BRAKE CALIPERS - FRONT
REMOVAL..............................22
DISASSEMBLY...........................23
CLEANING..............................24
INSPECTION............................24
ASSEMBLY.............................24
INSTALLATION...........................25
DISC BRAKE CALIPERS - REAR
REMOVAL..............................26
DISASSEMBLY...........................27
CLEANING..............................28
INSPECTION............................28
ASSEMBLY.............................28
INSTALLATION...........................29
DISC BRAKE CALIPER ADAPTER
REMOVAL..............................29
INSTALLATION...........................29
DISC BRAKE CALIPER GUIDE PINS
REMOVAL..............................30
INSTALLATION...........................30
DRUM
STANDARD PROCEDURE..................31
BRAKE DRUM MACHINING...............31
REMOVAL..............................31
INSTALLATION...........................31
FLUID
DIAGNOSIS AND TESTING.................31
BRAKE FLUID CONTAMINATION...........31
STANDARD PROCEDURE..................32
BRAKE FLUID LEVEL CHECKING..........32
SPECIFICATIONS........................32
RSBRAKES5-1

JUNCTION BLOCK
DESCRIPTION...........................32
OPERATION.............................32
REMOVAL..............................32
INSTALLATION...........................33
MASTER CYLINDER
DESCRIPTION...........................33
OPERATION.............................34
STANDARD PROCEDURE..................34
MASTER CYLINDER BLEEDING...........34
REMOVAL..............................34
DISASSEMBLY...........................35
ASSEMBLY.............................36
INSTALLATION...........................36
POWER BRAKE BOOSTER
DESCRIPTION...........................37
OPERATION.............................37
DIAGNOSIS AND TESTING.................38
POWER BRAKE BOOSTER...............38
REMOVAL..............................38
INSTALLATION...........................40
PROPORTIONING VALVE
DESCRIPTION...........................41
OPERATION.............................42
DIAGNOSIS AND TESTING.................42
PROPORTIONING VALVE (HEIGHT
SENSING).............................42
REMOVAL..............................43
INSTALLATION...........................43
ROTORS
DIAGNOSIS AND TESTING.................44BRAKE ROTOR........................44
STANDARD PROCEDURE..................47
BRAKE ROTOR MACHINING..............47
REMOVAL..............................48
INSTALLATION...........................48
SUPPORT PLATE - DRUM BRAKE
REMOVAL..............................48
INSTALLATION...........................49
WHEEL CYLINDERS
REMOVAL..............................50
INSPECTION............................50
INSTALLATION...........................50
PARKING BRAKE
DESCRIPTION...........................50
OPERATION.............................51
STANDARD PROCEDURE..................51
PARKING BRAKE AUTOMATIC ADJUSTER
MECHANISM RELEASE..................51
PARKING BRAKE AUTOMATIC ADJUSTER
RESET...............................51
LEVER - PARKING BRAKE
REMOVAL..............................52
INSTALLATION...........................53
SHOES - PARKING BRAKE
REMOVAL..............................53
INSTALLATION...........................58
ADJUSTMENTS..........................59
CABLES - PARKING BRAKE
REMOVAL..............................61
INSTALLATION...........................65
ADJUSTMENTS..........................66
BRAKES - BASE
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components:
²Brake pedal
²Power brake booster
²Master cylinder
²Brake tubes and hoses
²Proportioning valve (non-ABS vehicles only)
²Disc brakes
²Drum brakes
²Brake lamp switch
²Brake fluid level switch
²Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options.
The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other.For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)
Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly.
The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
come in contact with a hub mounted drum (drum for
5 - 2 BRAKES - BASERS

RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated.6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage.2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK1. Broken or missing anti-rattle
spring clips on shoes.1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING1. ABS wheel speed sensor or tone
wheel.1. Inspect, correct or replace faulty
component(s).
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD
BRAKING)1. One of the two hydraulic circuits to
the front brakes is malfunctioning.1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles).2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist.3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N1. Brake lamp switch out of
adjustment.1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment.1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
5 - 6 BRAKES - BASERS
BRAKES - BASE (Continued)

(6) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure
bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
ABS ICU Mounting Bolts To
Bracket11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts28 21 250
ABS CAB-To-HCU Mounting
Screws2Ð17
ABS Wheel Speed Sensor
Mounting Bolt12 Ð 105
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt47 35 Ð
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Disc Brake Caliper Guide
Pin Bolts35 26 Ð
Disc Brake Caliper Bleeder
Screw15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw10 Ð 80
Drum Brake Support Plate
Mounting Bolts130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts28 21 250
Master Cylinder Mounting
Nuts25 19 225
Power Brake Booster
Mounting Nuts28 21 250
Proportioning Valve
Mounting Bolts54 40 Ð
Proportioning Valve Axle
Bracket Mounting Bolt20 Ð 175
Parking Brake Lever (Pedal)
Mounting Bolts And Nut28 21 250
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
BASE BRAKE SYSTEM
Fig. 3 TOOL 6921 INSTALLED ON MASTER
CYLINDER
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
Tubes, Master Cylinder Bleeding 6920
5 - 8 BRAKES - BASERS
BRAKES - BASE (Continued)