2001 CHRYSLER VOYAGER lock

CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 60).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 55). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
(12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 54).
(13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 55).
Tighten the tube nuts to 17 N´m (145 in lbs.).
(14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.).(16) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.).
(17) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray.
(18) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing. Securely tighten hose clamp at air cleaner hous-
ing and throttle body.
(19) Secure the engine coolant filler neck to the
battery tray with its mounting screw.
(20) Install the battery, clamp and mounting nut.
(21) Install the positive battery cable on the bat-
tery.
(22) Install the negative battery cable on the bat-
tery.
(23) Install the battery thermal guard shield.
(24) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(25) Road test vehicle to ensure operation of the
brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. It is mounted to the body of
the vehicle above the rear axle (Fig. 61). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.
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 potentially
could result in increased stopping distance of the
vehicle.
Fig. 60 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
RSBRAKES - BASE5-41
POWER BRAKE BOOSTER (Continued)

OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)
Vehicles not equipped with ABS use a height sens-
ing proportioning valve.
The height sensing proportioning valve operates
similarly to a standard proportioning valve in the fol-
lowing way. As hydraulic pressure is applied to the
valve, full input hydraulic pressure is supplied to the
rear brakes up to a certain pressure 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 given ratio. Thus, on
light brake applications, approximately equal
hydraulic pressure will be transmitted to both the
front and rear brakes. Upon heavier brake applica-
tions, the hydraulic pressure transmitted to the rear
brakes will be lower than the front brakes. This will
prevent premature rear wheel lockup and skid.
Here is how the height sensing proportioning valve
differs from a standard proportioning valve. As the
height of the rear suspension changes, the height
sensing portion of the proportioning valve changes
the split point of the proportioning valve. When the
height of the rear suspension is low, the proportion-
ing valve interprets this as extra load and the split
point of the proportioning valve is raised to a higher
pressure to allow for more rear braking. When the
height of the rear suspension is high, the proportion-
ing valve interprets this as a light load and the split
point of the proportioning valve is lowered to a lower
pressure and rear braking is reduced.
The height sensing proportioning valve regulates
the pressure by sensing the load condition of thevehicle through the movement of the proportioning
valve actuator lever (Fig. 61). As the position of the
rear axle changes, depending on the load the vehicle
is carrying, the movement is transferred to the pro-
portioning valve. The proportioning valve adjusts the
hydraulic pressure accordingly.
The height sensing proportioning valve allows the
brake system to maintain the optimal front to rear
brake balance regardless of the vehicle load condi-
tion. Under a light load condition, hydraulic pressure
to the rear brakes is minimized. As the rear load con-
dition increases, so does the hydraulic pressure to
the rear brakes.
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE (HEIGHT SENSING)
CAUTION: The use of aftermarket load leveling or
load capacity increasing devices on this vehicle is
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 potentially
could result in increased stopping distance of the
vehicle.
When a premature rear wheel skid is obtained on a
brake application, it may be an indication that the
hydraulic pressure to the rear brakes is above the
specified output from the proportioning valve. This
condition indicates a possible malfunction of the
height sensing proportioning valve, which will
require testing to verify that it is properly controlling
the hydraulic pressure allowed to the rear brakes.
Premature rear wheel skid may also be caused by
contaminated front or rear brake linings.
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. This vehicles brake system is
not balanced for aftermarket brake shoe assem-
bly lining material.
If both front and rear brakes check OK, proceed
with the following test procedure for the height sens-
ing proportioning valve.
(1) Road test the vehicle to determine which rear
wheel brake is exhibiting premature wheel skid.
Fig. 61 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
5 - 42 BRAKES - BASERS
PROPORTIONING VALVE (Continued)

(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the chassis brake tube going to the
rear brake in question at the proportioning valve.
Remove the chassis brake tube coming from the junc-
tion block at the proportioning valve (Fig. 62).
(4) Install the appropriate fittings from Pressure
Test Fittings, Special Tool 6833, into the open ports
of the proportioning valve.
(5) Install the previously removed brake lines into
the Pressure Test Fittings. Tighten all tube nuts to
17 N´m (145 in. lbs.).
(6) Install a pressure gauge from Gauge Set, Spe-
cial Tool C-4007-A into the open port on each pres-
sure test fitting. Bleed air out of hose from pressure
test fittings to pressure gauges at the pressure
gauges. Then bleed air out of the brake line being
tested at that rear wheel brake bleeder.
(7) Remove the screw fastening the proportioning
valve actuator lever bracket to the rear axle. Raise
the actuator lever to the full-upward position.
(8) 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 vehicleis 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. (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/PROPOR-
TIONING VALVE - REMOVAL)
CAUTION: Do not attempt to adjust the height sens-
ing proportioning valve. If found to be defective,
replace the 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. Tighten all tube
nuts to 17 N´m (145 in. lbs.).
(11) If necessary, repeat the above steps on the
remaining side of the proportioning valve which con-
trol the other rear wheel brake.
(12) Attach the actuator lever and bracket to the
rear axle.
(13) Bleed rear brakes. (Refer to 5 - BRAKES -
STANDARD PROCEDURE)
(14) Road test vehicle.
WHEEL
BASEDRIVE
TRAINSALES CODE BRAKE SYSTEMSPLIT
POINTSLOPEINLET
PRESSURE
PSIOUTLET
PRESSURE
PSI
SWB FWD BRB-BGF159DISC/DRUM
W/O ANTILOCKVAR. .59 1000 PSI 675-875 PSI
REMOVAL - PROPORTIONING VALVE (HEIGHT
SENSING)
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the proportioning valve.
(2) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE).
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the four brake tubes from the inlet and
outlet ports of the proportioning valve (Fig. 62).
(4) Remove the two bolts attaching the proportion-
ing valve and bracket to the vehicle (Fig. 62).(5) Slide the bracket out from under rear track bar
bracket. Lower the valve down enough to pull its
actuator lever out of the axle bracket and remove the
proportioning valve from the vehicle.
INSTALLATION - PROPORTIONING VALVE
(HEIGHT SENSING)
(1) Install the end of the actuator lever through
the axle bracket grommet and slide the proportioning
valve bracket under the rear track bar body bracket
(Fig. 62).
(2) Install the proportioning valve attaching bolts
(Fig. 62). Tighten the attaching bolts to a torque of
54 N´m (40 ft. lbs.).
(3) Install the four chassis brake lines into the
inlet and outlet ports of the proportioning valve (Fig.
62). Tighten all tube nuts to a torque of 17 N´m (145
in. lbs.).
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it.
RSBRAKES - BASE5-43
PROPORTIONING VALVE (Continued)

hat style brake rotor) is used as the parking brake
drum.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment.
When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel.
The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park-
ing brake cables.
An equalizer bracket is used at the rear end of the
front parking brake cable to distribute tension
equally to each parking brake cable.
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RELEASE
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
This parking brake lever (pedal) mechanism is
designed so that the adjuster mechanism will rotate
only half a turn when the tension is released from
the parking brake cable. This eliminates the require-
ment to lock out the automatic adjuster when servic-
ing the parking brake lever (pedal) mechanism and
cables.
Use the following procedure to release the tension
from the parking brake cables and the automatic
adjuster in the parking brake lever (pedal) mecha-
nism.
(1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 76).
(2) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 77).
(3) Remove the equalizer from the front parking
brake cable.
(4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever (pedal) mechanism to rotate
around to its stop. This will remove the tension from
the adjuster and front park brake cable (Refer to 5 -BRAKES/PARKING BRAKE - STANDARD PROCE-
DURE).
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RESET
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
Fig. 76 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 77 Parking Brake Cable Attachment To
Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
RSBRAKES - BASE5-51
PARKING BRAKE (Continued)

(1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 76).
(2) Install the equalizer on the front parking brake
cable.
(3) Install the left rear and intermediate park
brake cable in the correct location on the parking
brake cable equalizer (Fig. 77).
(4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever (pedal) mechanism to tension the
park brake cables.
(5) Apply and release the parking brake lever
(pedal) one time. This will seat the parking brake
cables and allow the auto adjuster in the parking
brake lever (pedal) mechanism to correctly tension
the parking brake cables.
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE).
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel.
(6) Remove the steering column cover from the
lower instrument panel.
(7) Remove the reinforcement from the lower
instrument panel.
(8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 78).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable.
(10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.(11) Remove the lower bolt mounting the park
brake pedal to the body (Fig. 79).
(12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 79).
(13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 79).
Fig. 78 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 79 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
5 - 52 BRAKES - BASERS
PARKING BRAKE (Continued)

(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block.
(15) Remove park brake pedal release link from
park brake mechanism.
(16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
79).
(17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism.
(2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket.
(3) Install cable strand button into the clevis on
the park brake pedal mechanism.
(4) Install wiring harness connector on warning
indicator lamp ground switch.
(5) Install the park brake release rod on the
release mechanism of the park brake pedal.
(6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle.
(7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 79).
(8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 79).
(9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 79).
(10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.).
(11) Verify that the park brake pedal is in the fully
released (full up) position.
(12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 78).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer to 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism.
(16) Install the electrical junction block on the
instrument panel.
(17) Install the reinforcement on the lower instru-
ment panel.
(18) Install the steering column lower cover on the
lower instrument panel.(19) Install the silencer panel under the instru-
ment panel.
(20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door.
(22) Install the negative (ground) cable on the bat-
tery.
(23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) Set the parking brake.The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove the wheel and tire assembly.
(4) Remove the cotter pin and nut retainer (Fig.
80) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 81) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 82) from
the stub shaft of the outer C/V joint.
(7) Release the parking brake.
Fig. 80 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RSBRAKES - BASE5-53
LEVER (Continued)

(8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 83).(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 84).
(10) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 85).
Fig. 81 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 82 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 83 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 84 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5 - 54 BRAKES - BASERS
SHOES (Continued)

(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
86).
(12) Remove the rotor from the hub/bearing.
(13) Remove the horseshoe clip (Fig. 87) from the
retainer on the end of the park brake cable.
(14) Remove the end of the park brake cable from
the actuator lever on the adapter (Fig. 87).(15) Remove the end of the park brake cable from
the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in (Fig. 88) to compress
the locking tabs on the park brake cable retainer.
(16) Remove the attaching bolt from the wheel
speed sensor (Fig. 89). Then remove wheel speed sen-
sor from hub/bearing and adapter.
Fig. 85 Removing/Installing Caliper
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
Fig. 86 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 87 Park Brake Cable Attachment To Actuator
1 - ADAPTER
2 - PARK BRAKE CABLE
3 - ACTUATOR
4 - AXLE
5 - DRIVESHAFT
6 - PARK BRAKE CABLE RETAINER
7 - HORSESHOE CLIP
Fig. 88 Park Brake Cable Removal From Adapter
1 - DRIVESHAFT
2 - 1/2º WRENCH
3 - PARK BRAKE CABLE
4 - PARK BRAKE CABLE RETAINER
5 - ADAPTER
RSBRAKES - BASE5-55
SHOES (Continued)