2004 CHRYSLER VOYAGER brake

If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were removed from.
INSTALLATION - REAR DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments where the
shoes contact with a liberal amount of MopartMul-
tipurpose Lubricant, or equivalent.
(3) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
NOTE: The outboard shoes are different left to
right. They can be identified by a L or R stamped on
the clip.
(5) Install the outboard brake shoe on the disc
brake caliper. Be sure the outboard shoe is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(6) Carefully lower caliper and brake shoes over
rotor and onto adapter, reversing the removal proce-
dure (Fig. 16).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
(8) Install the wheel and tire assembly. Tighten
the wheel mounting 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.).
(9) Lower vehicle.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(10) Pump brake pedal several times to set brake
shoes to rotors.(11) Check fluid level in reservoir.
(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.BRAKE PADS/SHOES - REAR
DRUM
REMOVAL - REAR DRUM BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM
- REMOVAL)
NOTE: When creating slack in the park brake cables
by locking out the automatic adjuster, (Fig. 19) be
sure that the park brake pedal is in the released
(most upward) position.
(4) Create slack in the rear park brake cables.
Slack is created by grabbing exposed section of front
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake
cable just rearward ofonly the rearbody outrigger
bracket. (Fig. 19)
Fig. 19 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RSBRAKES - BASE5-19
BRAKE PADS/SHOES - REAR DISC (Continued)

(5) Remove adjustment lever spring (Fig. 20) from
adjustment lever and front brake shoe.
(6) Remove adjustment lever (Fig. 21) from leading
brake shoe.(7) Remove the brake shoe to brake shoe lower
return springs (Fig. 22) and (Fig. 23).
Fig. 20 Adjustment Lever Actuating Spring
1 - TRAILING BRAKE SHOE
2 - LEADING BRAKE SHOE
3 - AUTOMATIC ADJUSTER LEVER
4 - ADJUSTER LEVER ACTUATING SPRING
Fig. 21 Adjustment Lever
1 - AUTOMATIC ADJUSTER
2 - LEADING BRAKE SHOE
3 - AUTOMATIC ADJUSTER LEVER
Fig. 22 Remove/Install Brake Shoe Lower Return
Spring
1 - ANCHOR PLATE
2 - LOWER BRAKE SHOE RETURN SPRING
3 - REAR BRAKE SHOE
4 - FRONT BRAKE SHOE
5 - BRAKE SUPPORT PLATE
Fig. 23 Brake Shoe Lower Return Spring
1 - TRAILING BRAKE SHOE
2 - LEADING BRAKE SHOE
3 - RETURN SPRING
5 - 20 BRAKES - BASERS
BRAKE PADS/SHOES - REAR DRUM (Continued)

(8) Remove the tension clip (Fig. 24) attaching the
upper return spring to the automatic adjuster assem-
bly.
(9) Remove the brake shoe to brake shoe upper
return spring (Fig. 25).(10) Remove the trailing brake shoe assembly to
brake support plate hold down spring and pin (Fig.
26) from the brake shoe assembly.
(11) Remove the trailing brake shoe assembly from
the brake support plate, park brake actuating lever
and park brake actuating strut (Fig. 27). Remove the
automatic adjuster assembly from the leading brake
shoe.
Fig. 24 Tension Clip Attachment To Adjuster
1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
3 - AUTOMATIC ADJUSTER LEVER
4 - TENSION CLIP
5 - AUTOMATIC ADJUSTER ASSEMBLY
Fig. 25 Brake Shoe Upper Return Spring
1 - BRAKE SHOE RETURN SPRING
2 - LEADING BRAKE SHOE
3 - TRAILING BRAKE SHOE
Fig. 26 Trailing Brake Shoe Hold Down Spring And
Pin
1 - BRAKE SUPPORT PLATE
2 - HOLD DOWN SPRING AND PIN
3 - TRAILING BRAKE SHOE
Fig. 27 Trailing Brake Shoe Removal/Installation
1 - BRAKE SUPPORT PLATE
2 - LEADING BRAKE SHOE
3 - PARK BRAKE ACTUATING LEVER
4 - PARK BRAKE ACTUATING STRUT
5 - TRAILING BRAKE SHOE
RSBRAKES - BASE5-21
BRAKE PADS/SHOES - REAR DRUM (Continued)

(12) Remove the leading brake shoe assembly to
brake support plate hold down spring and pin (Fig.
28) from the brake shoe. Remove the leading brake
shoe from the brake support plate.
(13) Remove the park brake actuator (Fig. 29)
from the leading brake shoe and transfer to the
replacement brake shoe.INSPECTION - REAR DRUM BRAKE SHOE
LINING
(1) Remove the tire and wheel assembly from the
vehicle
(2) Remove the rear brake adjusting hole plug
found in the brake support.
(3) Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the
notches on the adjusting screw star wheel.
(4) Insert Tool C-3784 into brake adjusting hole
and engage notches of brake adjusting screw star
wheel. Release brake by prying down with adjusting
tool.
(5) Remove the rear brake drum from the rear hub
and bearing assembly. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL)
(6) Inspect brake lining for wear, shoe alignment,
and or contamination from grease or brake fluid.
INSTALLATION - REAR DRUM BRAKE SHOES
(1) Lubricate the eight shoe contact areas on the
support plate and anchor, (Fig. 30) using the
required special MopartBrake Lubricant or equiva-
lent.
(2) Install leading brake shoe on brake support
plate. Install the leading brake shoe hold down
spring and pin (Fig. 28) on the brake shoe.
(3) Install the park brake actuator strut (Fig. 31)
on the leading brake shoe. Then install the park
brake actuator lever on the strut (Fig. 31).
Fig. 28 Leading Brake Shoe Hold Down Spring And
Pin
1 - PARK BRAKE ACTUATING LEVER
2 - BRAKE SUPPORT PLATE
3 - LEADING BRAKE SHOE
4 - HOLD DOWN SPRING AND PIN
Fig. 29 Park Brake Actuator Plate
1 - RETAINING CLIP
2 - BRAKE SHOE ASSEMBLY
3 - ACTUATOR PLATE
Fig. 30 Brake Support Plate Contact Areas
1 - REAR BRAKE SUPPORT PLATE
5 - 22 BRAKES - BASERS
BRAKE PADS/SHOES - REAR DRUM (Continued)

(4) Install the automatic adjuster screw on the
leading brake shoe. Then install the trailing brake
shoe on the park brake actuating lever and park
brake actuating strut (Fig. 27). Position trailing
brake shoe on brake support plate.
(5) Install the brake shoe hold down pin and
spring on the trailing brake shoe (Fig. 26).
(6) Install the brake shoe to brake shoe upper
return spring (Fig. 25).
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 24). If
it is located on a non-threaded area of the adjuster,
the function of the automatic adjuster will be
affected.
(7) Install the tension clip (Fig. 24) attaching the
upper return spring to the automatic adjuster assem-
bly.
(8) Install the brake shoe to brake shoe lower
return springs on the brake shoes (Fig. 22) and (Fig.
23).
(9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 21).
(10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 20).
(11) Verify that the automatic adjuster lever has
positive contact with the star wheel on the automatic
adjuster assembly.
(12) When all components of both rear brake
assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.(13) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(14) Install the rear brake drums on the hubs.
(15) Adjust rear brake shoes.
(16) Install the wheel and tire assembly.
(17) 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.).
(18) Lower the vehicle.
(19) Push the parking brake lever (pedal) to the
floor once and release pedal. This will automatically
remove the slack from and correctly adjust the park-
ing brake cables.
(20) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE SHOES
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
NOTE: Before raising the vehicle, verify the parking
brake lever is fully released.
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove rubber plug from rear brake adjusting
hole in the rear brake support plate.
(3) Insert a thin screwdriver through the adjusting
hole in the support plate and against the star wheel
of the adjusting screw. Move handle of the tool
upward rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated.
(4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel.Care should be taken so as not to bend
adjusting lever or distort lever spring.
(5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag.
(6) Repeat the above adjustment at the other rear
wheel.
(7) Install the adjusting hole rubber plugs back in
the rear brake support plates.
(8) Lower the vehicle.
Fig. 31 Park Brake Components Assembled On
Leading Brake Shoe
1 - PARK BRAKE CABLE
2 - LEADING BRAKE SHOE
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER
5 - BRAKE SUPPORT PLATE
RSBRAKES - BASE5-23
BRAKE PADS/SHOES - REAR DRUM (Continued)

DISC BRAKE CALIPER -
FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)
(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 front wheel and tire assembly.
(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 2 caliper guide pin bolts.
(6) Remove the brake caliper from the adapter.
REMOVAL - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES)
(1) Using a brake pedal holding tool, depress the
brake pedal past its first one inch of travel and hold
it in this position. This will isolate the master cylin-
der from the brake hydraulic system and will not
allow the brake fluid to drain out of the master cyl-
inder reservoir when the lines are opened.
(2) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
(3) Remove the front tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 32). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Discard the
washers.
(5) Remove the two brake caliper guide pin bolts
(Fig. 32).
(6) Remove the disc brake caliper from the disc
brake adapter.
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (DISC/DISC BRAKES)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING or INSPECTION in
this section.(1) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss.
(2) Repeat this procedure on the remaining bush-
ing.
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
Fig. 32 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5 - 24 BRAKES - BASERS

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.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 33). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.CLEANING - CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or MopartNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
²Brake fluid leaks in and around boot area and
inboard lining
²Ruptures, brittleness or damage to the piston
dust boot
²Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
(DISC/DISC BRAKES)
(1) Fold the guide pin bushing in half lengthwise.
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
(2) Insert the folded bushing into the caliper
mounting boss using your fingers from the rear of
the caliper.
Fig. 33 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
RSBRAKES - BASE5-25
DISC BRAKE CALIPER - FRONT (Continued)

(3) Unfold the bushing using your fingers or a
wooden dowel until the bushing is fully seated into
the caliper housing. The bushing flanges should be
seated evenly on both sides of the bushing hole.
(4) Lubricate inside surfaces of bushing using
MopartDielectric Grease or equivalent.
(5) Repeat the procedure for remaining bushing.
ASSEMBLY - CALIPER PISTON AND SEAL
NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid
and install it in the groove of the caliper bore. The
seal should be started at one area of the groove and
gently worked around and into the groove (Fig.
34)using only your clean fingers to seat it.
(2) Coat the new piston boot with clean brake
fluid.
(3) Position the dust boot over the piston after
coating it with brake fluid.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 35).
(5) Position the dust boot into the counterbore of
the caliper assembly piston bore.
(6) Using a hammer and Installer, Special Tool
C-4689 or C-4842 (depending on piston size), and
Handle, Special Tool C-4171, drive the boot into the
counterbore of the caliper as necessary (Fig. 36).(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
Fig. 34 Installing New Piston Seal
1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
Fig. 35 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 36 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
5 - 26 BRAKES - BASERS
DISC BRAKE CALIPER - FRONT (Continued)