2002 CHRYSLER VOYAGER Service Manual

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Page 209 of 2399

CHRYSLER VOYAGER 2002 Service Manual (22) Remove the lower return spring (Fig. 140)
from the leading and trailing park brake shoes.
(23) Remove the hold down spring and pin (Fig.
141) from the leading park brake shoe.(24) Remove the adju

Page 210 of 2399

CHRYSLER VOYAGER 2002 Service Manual (26) Remove the upper return springs (Fig. 144)
from the trailing park brake shoe.
(27) Remove the hold down spring and pin (Fig.
145) from the trailing park brake shoe.(28) Remove the trailing park b

(26) Remove the upper return springs (Fig. 144)
from the trailing park brake shoe.
(27) Remove the hold down spring and pin (Fig.
145) from the trailing park brake shoe.(28) Remove the trailing park brake shoe from the
adapter.
(29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(3) Install the hold down spring and pin (Fig. 145)
on the trailing park brake shoe.
(4) Install the upper return springs (Fig. 144) on
the trailing park brake shoe.
(5) Install the upper return springs on the leading
park brake shoe (Fig. 143). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter.
(6) Install the adjuster (Fig. 142) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(7) Install the hold down spring and pin (Fig. 141)
on the leading park brake shoe.
(8) Install the lower return spring (Fig. 140) on
the leading and trailing park brake shoes.When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 140).
(9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle.
(10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 146).
Fig. 144 Upper Return Springs
1 - TRAILING PARK BRAKE SHOE
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - UPPER RETURN SPRINGS
Fig. 145 Trailing Brake Shoe Hold Down Pin And
Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
RSBRAKES - BASE5-81
SHOES - PARKING BRAKE (Continued)
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Page 211 of 2399

CHRYSLER VOYAGER 2002 Service Manual (11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 137).
(12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolt

(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 137).
(12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.).
(13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 134). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs).
(14) FWD only - Install the wheel speed sensor in
the following fashion:
(a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.(15) Install the park brake cable into its mounting
hole in the adapter.Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter.
(16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 132).
(17) Attach park brake cable to adapter using
mounting bolt.
(18) Remove the locking pliers (Fig. 128) from the
front park brake cable.
(19) Adjust the park brake drum-in-hat brake
shoes. (Refer to 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS).
(20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 130).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 129).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.).
(23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 127) on the stub shaft of
the outer C/V joint.
(24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.).
(26) AWD only - Install the spring washer (Fig.
126) on the stub shaft of the outer C/V joint.
(27) AWD only - Install the nut retainer and cotter
pin (Fig. 125) on the stub shaft of the outer C/V joint.
(28) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N´m (100 ft. lbs.).
(29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
Fig. 146 Adapter Installed On Mounting Bolts (AWD
Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
5 - 82 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)
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Page 212 of 2399

CHRYSLER VOYAGER 2002 Service Manual ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully

Page 213 of 2399

CHRYSLER VOYAGER 2002 Service Manual (7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
t

Page 214 of 2399

CHRYSLER VOYAGER 2002 Service Manual BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................85
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................85
D

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................85
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................85
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............86
DESCRIPTION - TRACTION CONTROL
SYSTEM............................86
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 86
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............87
OPERATION - TRACTION CONTROL
SYSTEM............................87
CAUTION
CAUTIONS..........................88
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................88
SPECIFICATIONS
ABS FASTENER TORQUE...............89
TONE WHEEL RUNOUT................89
WHEEL SPEED SENSOR AIR GAP........89
FRONT WHEEL SPEED SENSOR
REMOVAL.............................89
INSTALLATION.........................89
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................90INSTALLATION.........................90
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................91
INSTALLATION.........................91
TONE WHEEL
INSPECTION - TONE WHEEL..............92
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................92
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................93
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................99
OPERATION...........................99
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION........................100
OPERATION..........................100
REMOVAL
REMOVAL - LHD.....................100
REMOVAL - RHD.....................101
DISASSEMBLY - ICU...................103
ASSEMBLY - ICU......................103
INSTALLATION
INSTALLATION - LHD.................104
INSTALLATION - RHD.................105
BRAKES - ABS
DESCRIPTION
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 - ANTILOCK BRAKE SYSTEM
(EXPORT)
Four-wheel disc antilock brakes are standard on all
models. The Mark 20e antilock brake system is used
on all models. Depending on whether the vehicle is a
left-hand drive (LHD) or right-hand drive (RHD)
model, the integrated control unit (ICU) is located in
one of two locations. On LHD models, the ICU is
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
RSBRAKES - ABS5-85
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Page 215 of 2399

CHRYSLER VOYAGER 2002 Service Manual DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rea

DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
tioning valve. The EVBP system uses the ABS sys-
tem to control the slip of the rear wheels in partial
braking range. The braking force of the rear wheels
is controlled electronically by using the inlet and out-
let 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
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-
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
5 - 86 BRAKES - ABSRS
BRAKES - ABS (Continued)
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Page 216 of 2399

CHRYSLER VOYAGER 2002 Service Manual 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
an

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 VARIABLE BRAKE
PROPORTIONING
Upon entry into EVBP 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
the rear brake pressure, the outlet valve is switched
off and the inlet valve is pulsed. This increases thepressure to the rear brakes. This back-and-forth pro-
cess will continue until the required slip difference is
obtained. At the end of EVBP braking (brakes
released) the fluid in the LPA drains back to the
master cylinder by switching on the outlet valve and
draining through the inlet valve check valve. At the
same time the inlet valve is switched on in case of
another brake application.
The EVBP will remain functional during many
ABS fault modes. If both the red BRAKE and amber
ABS warning indicators are illuminated, the EVBP
may not be functioning.
OPERATION - TRACTION CONTROL SYSTEM
The traction control module monitors wheel speed.
During acceleration, if the module detects front
(drive) wheel slip and the brakes are not applied, the
module enters traction control mode. Traction control
operation proceeds in the following order:
(1) Close the normally open isolation valves.
(2) Start the pump/motor and supply volume and
pressure to the front (drive) hydraulic circuit. (The
pump/motor runs continuously during traction con-
trol operation.)
(3) Open and close the build and decay valves to
maintain minimum wheel slip and maximum trac-
tion.
The cycling of the build and decay valves during
traction control is similar to that during antilock
braking, except the valves work to control wheel spin
by applying the brakes, whereas the ABS function is
to control wheel skid by releasing the brakes.
If the brakes are applied at anytime during a trac-
tion control cycle, the brake lamp switch triggers the
controller to switch off traction control.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves allow
pressure and volume to return to the master cylinder
reservoir when not consumed by the build and decay
valves. These valves are necessary because the
pump/motor supplies more volume than the system
requires.
TRACTION CONTROL LAMP
The traction control system is enabled at each igni-
tion cycle. It may be turned off by depressing the
Traction Control Off switch button when the ignition
is in the ON position. The traction control function
lamp (TRAC OFF) illuminates immediately upon
depressing the button.
The traction control function lamp illuminates dur-
ing a traction control cycle, displaying TRAC.
If the CAB calculates that the brake temperatures
are high, the traction control system becomes inoper-
ative until a time-out period has elapsed. During this
RSBRAKES - ABS5-87
BRAKES - ABS (Continued)
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