2003 CHRYSLER VOYAGER air condition

(1) Depress the brake pedal past its first inch of
travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
master cylinder from the brake hydraulic system dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir.
(2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove rear wheel and tire assembly from
vehicle.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper. There are two washers (one
on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers.
(5) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 37).
(6) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 38).
(7) If the brake rotor requires removal, it can now
be removed by first removing the retainer clips from
the wheel mounting studs, then pulling the rotor
straight off the studs.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers.
(2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out.
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
Fig. 37 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 38 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
5 - 28 BRAKES - BASERS
DISC BRAKE CALIPER - REAR (Continued)
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CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
49). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
49).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
INSTALLATION - RHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 51). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
51). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
47).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
PEDAL TORQUE SHAFT - RHD
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
(3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Remove
the link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled.
(4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 54). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled.
(5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig.
55).
(6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 55).
(7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
INSTALLATION
(1) Lubricate both ends of the torque shaft with
MS-4517 Lubricant or equivalent and install the
torque shaft from the left side reversing the removal
procedure.
(2) Install the brake booster bracket on the left
end of the shaft.
(3) Install the retaining nut for the brake booster
bracket in the engine compartment. Tighten the
mounting nut to a torque of 29 N´m (250 in. lbs.).
RSBRAKES - BASE5-39
MASTER CYLINDER (Continued)
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(4) Install the four brake booster retaining nuts
inside the passenger compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(5) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-tacts the booster input rod. Also coat the surface of
the brake pedal torque shaft pin where it contacts
the brake pedal link.
CAUTION: When installing the power brake booster
input rod on the brake pedal torque shaft pin, do
not reuse the old retaining clip.
(6) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 54).
CAUTION: When installing the brake pedal link on
the brake pedal torque shaft pin, do not reuse the
old retaining clip.
(7) Connect the brake pedal link to the torque
shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)
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.
(10) 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)
(11) Road test vehicle to ensure proper operation of
the brakes.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster mounts on the engine
compartment side of the dash panel. It is connected
to the brake pedal by the input (push) rod (Fig. 56).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
All vehicles use a 270 mm single diaphragm vac-
uum power brake booster.
Vehicles equipped with Disc/Disc brakes use a dif-
ferent power brake booster than vehicles equipped
with Disc/Drum brakes. Differences between the two
are internal. Service is the same for all boosters.
Fig. 54 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
Fig. 55 BOOSTER, TORQUE SHAFT AND PEDAL
MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT
5 - 40 BRAKES - BASERS
PEDAL TORQUE SHAFT - RHD (Continued)
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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 the
vehicle through the movement of the proportioning
valve actuator lever (Fig. 72). 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 helpersprings 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.
(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. 73).
(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.
NOTE: Actuator rod is a linear spring and is meant
to flex by design. When rod is raised, it will have
some curvature to it.
Fig. 72 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
RSBRAKES - BASE5-49
PROPORTIONING VALVE (Continued)
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BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................75
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................75
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............75
DESCRIPTION - TRACTION CONTROL
SYSTEM............................76
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 76
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............77
OPERATION - TRACTION CONTROL
SYSTEM............................77
CAUTION
CAUTIONS..........................78
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................78
SPECIFICATIONS
ABS FASTENER TORQUE...............79
TONE WHEEL RUNOUT................79
WHEEL SPEED SENSOR AIR GAP........79
FRONT WHEEL SPEED SENSOR
REMOVAL.............................79
INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................80INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................81
INSTALLATION.........................81
TONE WHEEL
INSPECTION - TONE WHEEL..............82
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................82
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................83
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................89
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................90
REMOVAL
REMOVAL - LHD......................90
REMOVAL - RHD......................91
DISASSEMBLY - ICU....................93
ASSEMBLY - ICU.......................94
INSTALLATION
INSTALLATION - LHD..................94
INSTALLATION - RHD..................95
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.
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-
RSBRAKES - ABS5-75
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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 the
pressure 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 themaster 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
ªthermo-protection mode,º the traction control func-
tion lamp illuminates TRAC OFF; note that no trou-
ble code is registered.
RSBRAKES - ABS5-77
BRAKES - ABS (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACINGS
HAVE FRACTURED
INTO SMALL PIECESLeak at rear main or transaxle input
shaft sealReplace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and disc
(2.5L TD)..
Excessive heat from slippage Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).
SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS
ON INPUT SHAFT
SPLINESClutch disc hub splines damaged
during installationClean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly, or
clutch disc, and/or input shaft if splines are
severely damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on
splines of input shaft and discClean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATEOccurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.Replace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).
Clutch cover diaphragm spring
damaged during transaxle installationReplace modular clutch assembly (2.4L Gas)
or clutch cover and disc (2.5L TD).
Release fork bent, loose, or
damagedReplace fork if worn or damaged
Air in clutch hydraulic circuit. Allow system to self-bleed or replace
hydraulic components.
Leak in clutch hydraulic circuit. Replace worn/damaged/leaking hydraulic
components.
Clutch pedal requires
excessive force (high
release load).Clutch disc is worn. Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models).
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings at clutch pedal
pivot or master cylinder pushrod.
Clutch pedal return spring worn out Lubricate or replace return spring
CLUTCH PEDAL
SQUEAKS DURING
OPERATIONClutch release lever pivot stud has
inadequate lubricationLubricate or replace clutch release lever
RSCLUTCH6-5
CLUTCH (Continued)
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(2) Install clutch release bearing to lever. Apply
grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).
(3) Apply grease to pivot ball, and on release lever
at slave cylinder contact point.
(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 12).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 13).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
Fig. 10 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 11 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 12 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
6 - 8 CLUTCHRS
CLUTCH RELEASE LEVER AND BEARING (Continued)
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