2001 DODGE TOWN AND COUNTRY steering

CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(12) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 55). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to
power brake booster (Fig. 55).
(15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Inside vehicle, remove silencer panel under
instrument panel below steering column.
(18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 56).
Fig. 54 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 55 MASTER CYLINDER MOUNTING
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 56 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
RSBRAKES - BASE5-39
POWER BRAKE BOOSTER (Continued)
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(19) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 57).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 58).
CAUTION: Do not attempt to disassemble the power
brake vacuum booster it is serviced ONLY as a
complete assembly.INSTALLATION - POWER BRAKE BOOSTER
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 58).
It may be necessary to push in on booster input rod
as it is guided through the dash panel.
(2) Install the four nuts mounting the booster to
the dash panel (Fig. 57). Tighten the mounting nuts
to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 59).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(6) Install the silencer panel below the steering
column.
(7) Connect vacuum hose to check valve on power
brake booster.
Fig. 57 BOOSTER MOUNTING
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 58 BOOSTER REMOVAL/INSTALLATION
Fig. 59 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
5 - 40 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)
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more than 0.013 mm (0.0005 inch), the rotor should
be refaced or replaced. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE).
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP-
1910 on steering arm. The dial indicator plunger
should contact braking surface of rotor approximately
ten millimeters from edge of rotor (Fig. 65). Check
lateral runout on both sides of the rotor, marking the
low and high spots on both. Runout limits can be
found in the table at the end of this brake rotor
information.
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing the
rotor from the hub, place a chalk mark across both
the rotor and the one wheel stud closest to where the
high runout measurement was taken. This way, the
original mounting spot of the rotor on the hub is
indexed (Fig. 66).
Remove the rotor from the hub.NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an
accurate indicator reading.
Mount Dial Indicator, Special Tool C-3339, and
Mounting Adaptor, Special Tool SP-1910, to the steer-
ing knuckle. Position the indicator stem so it contacts
the hub face near the outer diameter. Care must be
taken to position stem outside of the stud circle, but
inside of the chamfer on the hub rim (Fig. 67).
Hub runout should not exceed 0.03 mm (0.0012
inch). If runout exceeds this specification, the hub
Fig. 64 Checking Rotor For Thickness
1 - CALIPER
Fig. 65 Checking Rotor Runout
1 - SPECIAL TOOL SP-1910
2 - 10 MILLIMETERS FROM EDGE
3 - DISC SURFACE
4 - SPECIAL TOOL C-3339
Fig. 66 Marking Rotor and Wheel Stud
1 - CHALK MARK
RSBRAKES - BASE5-45
ROTORS (Continued)
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BRAKE ROTOR LIMITS
Braking RotorRotor
ThicknessMinimum
Rotor
ThicknessRotor
Thickness
VariationRotor
Runout*
Front Rotor -
Disc/Drum Brakes
(TRW)27.87±28.13
mm
1.097-1.107
in.25.3 mm
0.996 in.0.009 mm
0.0004 in.0.035 mm
0.0014 in.
Front Rotor -
Disc/Disc Brakes
(Teves)27.90±28.10
mm
1.098-1.106
in.25.3 mm
0.996 in.0.008 mm
0.0003 in.0.035 mm
0.0014 in.
Rear Rotor12.25±12.75
mm
0.482 -0.502
in.11.25 mm
0.443 in.0.013 mm
0.0005 in.0.14 mm
0.0055 in.
*
TIR Total Indicator Reading (Measured On Vehicle)
REMOVAL - FRONT BRAKE ROTOR
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly.
(3) Remove the two mounting bolts securing the
disc brake caliper adapter with brake caliper to the
steering knuckle (Fig. 72).(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 72).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove any retainer clips from the wheel
mounting studs.
(6) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 72).
INSTALLATION - FRONT BRAKE ROTOR
(1) Install the brake rotor back on the hub and
bearing (Fig. 72).
(2) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 72).
(3) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
Fig. 72 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
5 - 48 BRAKES - BASERS
ROTORS (Continued)
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(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)
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(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)
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BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION...........................67
OPERATION.............................67
CAUTION...............................69
STANDARD PROCEDURE..................70
ANTILOCK BRAKE SYSTEM BLEEDING.....70
SPECIFICATIONS........................71
FRONT WHEEL SPEED SENSOR
REMOVAL..............................71
INSTALLATION...........................71
REAR WHEEL SPEED SENSOR - AWD
REMOVAL..............................72
INSTALLATION...........................72
REAR WHEEL SPEED SENSOR - FWD
REMOVAL..............................73INSTALLATION...........................74
TONE WHEEL
INSPECTION............................74
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING.................74
TRACTION CONTROL SWITCH............74
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION...........................75
OPERATION.............................75
REMOVAL..............................76
DISASSEMBLY...........................77
ASSEMBLY.............................77
INSTALLATION...........................77
BRAKES - ABS
DESCRIPTION - ANTILOCK BRAKE SYSTEM
This section covers the physical and operational
descriptions and the on-car service procedures for the
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control.
The purpose of the antilock brake system (ABS) is
to prevent wheel lockup under braking conditions on
virtually any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
DESCRIPTION - ELECTRONIC BRAKE
DISTRIBUTION
Vehicles equipped with ABS use electronic brake
distribution (EBD) to balance front-to-rear braking.
The EBD is used in place of a rear proportioning
valve. The EBD system uses the ABS system to con-
trol the slip of the rear wheels in partial braking
range. The braking force of the rear wheels is con-
trolled electronically by using the inlet and outlet
valves located in the integrated control unit (ICU).
DESCRIPTION - TRACTION CONTROL SYSTEM
Traction control reduces wheel slip and maintains
traction at the driving wheels at speeds below 56
km/h (35 mph) when road surfaces are slippery. The
traction control system reduces wheel slip by braking
the wheel that is losing traction.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves are
included on vehicles with traction control. These
valves are located inside the HCU and cannot be ser-
viced separately from the HCU.
TRACTION CONTROL LAMP
The traction control function lamp is located in the
transmission range indicator display of the instru-
ment cluster, displaying TRAC, TRAC OFF or nei-
ther depending on system mode.
The TRAC OFF lamp is controlled by a Traction
Control Off switch that is a momentary contact type
switch. The Traction Control Off switch is located on
the steering column upper shroud.
OPERATION - ANTILOCK BRAKE SYSTEM
There are a few performance characteristics of the
Mark 20e Antilock Brake System that may at first
seem abnormal, but in fact are normal. These char-
acteristics are described below.
NORMAL BRAKING
Under normal braking conditions, the ABS func-
tions the same as a standard base brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS BRAKING
ABS operation is available at all vehicle speeds
above 3±5 mph. If a wheel locking tendency is
detected during a brake application, the brake sys-
RSBRAKES - ABS5-67
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tem enters the ABS mode. During ABS braking,
hydraulic pressure in the four wheel circuits is mod-
ulated to prevent any wheel from locking. Each
wheel circuit is designed with a set of electric sole-
noids to allow modulation, although for vehicle sta-
bility, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into three 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).
NOISE AND BRAKE PEDAL FEEL
During ABS braking, some brake pedal movement
may be felt. In addition, ABS braking will create
ticking, popping, or groaning noises heard by the
driver. This is normal and is 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 is 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 than 3 mph or during
an ABS stop where ABS is no longer required. These
conditions 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 sur-
face activates ABS because of the wheel hop caused
by the bumps.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
lockup, 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±30 percent. This means
that the wheel rolling velocity is 25±30 percent less
than that of a free rolling wheel at a given vehicle
speed. This slip may result in some tire chirping,
depending on the road surface. This sound should not
be interpreted as total wheel lockup.Complete wheel lockup normally leaves black tire
marks on dry pavement. The ABS will not leave dark
black tire marks since the wheel never reaches a
fully locked condition. However, tire marks may 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.
The ABS warning lamp will also be on for up to 5
seconds after the ignition is turned on. When the
vehicle is first driven off, a humming may be heard
or felt by the driver at approximately 20±40 kph
(12±25 mph). All of these conditions are a normal
function of ABS as the system is performing a diag-
nosis check.
PREMATURE ABS CYCLING
Symptoms of premature ABS cycling include: click-
ing sounds from the solenoid valves; pump/motor
running; and pulsations in the brake pedal. Prema-
ture ABS cycling can occur at any braking rate of the
vehicle and on any type of road surface. Neither the
red BRAKE warning lamp, nor the amber ABS warn-
ing lamp, illuminate and no fault codes are stored in
the CAB.
Premature ABS cycling is a condition that needs to
be correctly assessed when diagnosing problems with
the antilock brake system. It may be necessary to use
a DRB scan tool to detect and verify premature ABS
cycling.
Check the following common causes when diagnos-
ing premature ABS cycling: damaged tone wheels;
incorrect tone wheels; damaged steering knuckle
wheel speed sensor mounting bosses; loose wheel
speed sensor mounting bolts; excessive tone wheel
runout; or an excessively large tone wheel-to-wheel
speed sensor air gap. Give special attention to these
components when diagnosing a vehicle exhibiting
premature ABS cycling.
After diagnosing the defective component, repair or
replace it as required. When the component repair or
replacement is completed, test drive the vehicle to
verify that premature ABS cycling has been cor-
rected.
OPERATION - ELECTRONIC BRAKE
DISTRIBUTION
Upon entry into EBD the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure, the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
hydraulic control unit (HCU) resulting in a drop in
fluid pressure to the rear brakes. In order to increase
5 - 68 BRAKES - ABSRS
BRAKES - ABS (Continued)
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