2004 CHRYSLER VOYAGER wheel

(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

INSTALLATION
INSTALLATION - FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system (TRW -
disc/drum brake combination and Continental Teves
- disc/disc brake combination). If calipers are inter-
changed, improper performance, noise and
increased stopping distance can occur.
(1) Completely retract the caliper piston back into
piston bore of the caliper. Use a C-clamp to retract
the piston if necessary. Place a wood block over the
piston before installing the C-clamp to avoid damag-
ing the piston.
CAUTION: Use care when installing the brake cali-
per assembly onto the steering knuckle, so that the
seals on the caliper guide pin bushings do not get
damaged by the steering knuckle bosses.
(2) Carefully position the brake caliper and shoes
over the brake rotor and adapter.
(3) Install the caliper guide pin bolts and tighten
to a torque of 35 N´m (26 ft. lbs.).Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
(4) Install the anti-rattle clip on the outboard side
of the caliper. Start the clip into the holes on the cal-
iper, then stretch the clip legs past the abutments on
the caliper adapter.
CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
copper washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special fitting washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N´m (35 ft.
lbs.).
(6) 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.).
(7) Lower the vehicle.
(8) Remove the brake pedal depressor (holding)
tool.
(9) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
INSTALLATION - FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system (TRW -
disc/drum brake combination and Continental Teves
- disc/disc brake combination). If calipers are inter-
changed, improper performance, noise and
increased stopping distance can occur.
(1) Completely retract the caliper piston back into
the bore of the caliper. Use a C-clamp to retract the
piston if necessary. Place a wood block over the pis-
ton before installing the C-clamp to avoid damaging
the piston.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(2) Install the disc brake caliper over the brake
shoes on the brake caliper adapter.
(3) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N´m (26 ft. lbs.) (Fig.
32).
(4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 32). Install NEW copper
washers on each side of the hose fitting as the banjo
bolt is guided through the fitting. Thread the banjo
bolt into the caliper and tighten it to a torque of 47
N´m (35 ft. lbs.).
(5) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(6) Lower the vehicle.
(7) Remove the brake pedal holding tool.
(8) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - BASE - STANDARD PROCEDURE).
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
DISC BRAKE CALIPER - REAR
REMOVAL - REAR DISC BRAKE CALIPER
NOTE: Handling of the rotor and caliper, must be
done in such a way as to avoid damage to the rotor
and scratching or nicking of lining on the brake
shoes.
RSBRAKES - BASE5-27
DISC BRAKE CALIPER - FRONT (Continued)

(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)

(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this
section.
INSTALLATION - REAR DISC BRAKE CALIPER
(1) Completely retract caliper piston back into pis-
ton bore of the caliper.
(2) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.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.
(3) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 38).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to cross-thread the cal-
iper guide pin bolts.
(4) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
washers.
(5) Install the brake hose on the caliper. To do
this, first place one NEW special copper washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N´m (35 ft.
lbs.).
(6) Install the wheel and tire assembly.
Fig. 40 Installing New Piston Seal
1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
Fig. 41 Installing Piston Into Caliper Bore
1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 42 Installing Dust Boot
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
5 - 30 BRAKES - BASERS
DISC BRAKE CALIPER - REAR (Continued)

(7) 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.).
(8) Lower the vehicle.
(9) Remove the brake pedal depressor (holding)
tool.
(10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)
(11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
DISC BRAKE CALIPER
ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove front wheel and tire assembly, disc
brake caliper and brake shoes. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL)
(3) Remove two bolts fastening adapter to steering
knuckle, then remove disc brake caliper adapter.
INSTALLATION - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Place adapter over brake rotor and align
adapter mounting holes to knuckle.
CAUTION: Adapter mounting bolts have a special
DacrometTcoating applied to resist corrosion. If
mounting bolts need to be replaced, use only
MoparTreplacement parts.
(2) Install adapter mounting bolts and tighten to
169 N´m (125 ft. lbs.) torque.
(3) Install brake shoes, disc brake caliper and
wheel and tire assembly. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
INSTALLATION)
(4) Lower vehicle.
(5) Pump the brake pedal several times to set the
pads to the brake rotor.
(6) Check and adjust brake fluid level as neces-
sary.
DISC BRAKE CALIPER GUIDE
PINS
REMOVAL - DISC BRAKE CALIPER GUIDE PINS
(DISC/DRUM BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 43).
(4) Remove the disc brake caliper from the disc
brake caliper adapter and hang it out of the way
using wire or a bungee cord. Use care not to overex-
tend the brake hose when doing this.
(5) Remove the guide pins and boots from the
adapter as shown (Fig. 44).
INSTALLATION - DISC BRAKE CALIPER GUIDE
PINS (DISC/DRUM BRAKES)
(1) Lubricate the guide pins and inside the boots
with the packet supplied with the service kit, Syth-
eso GLK-1 lubricant or equivalent.
(2) Install the guide pins and boots in the adapter
as shown (Fig. 44). The boots have grooves built into
their inner lips to fit onto the pins and adapter.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
Fig. 43 Brake Caliper Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
RSBRAKES - BASE5-31
DISC BRAKE CALIPER - REAR (Continued)