2004 CHRYSLER VOYAGER torque

Use only brake fluid that was stored in a tightly-
sealed container. DO NOT use petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only Mopar tBrake
Fluid or equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is located
on the driver's side of the front suspension cradle/
crossmember below the master cylinder (Fig. 44).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block. (2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following: (a) Disconnect the battery positive cable.
(b) Remove the battery (Refer t o 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). (c) Disconnect the vacuum hose connector at the
tank built into the battery tray. (d) Remove the screw securing the coolant filler
neck to the battery tray. (e) Remove the battery tray (Refer t o 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system. (4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 44). (5) Remove the primary and secondary brake
tubes from the top of the junction block. (6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.). (2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
5s - 32 BRAKESRS
FLUID (Continued)

(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.). (4) If the vehicle is equipped with speed control,
perform the following: (a) Install the speed control servo with its
mounting nuts. (b) Connect the wiring harness to the speed con-
trol servo. (c) Install the battery tray (Refer t o 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION). (d) Install the screw securing the coolant filler
neck to the battery tray. (e) Reconnect the vacuum hose connector at the
tank built into the battery tray. (f) Install the battery (Refer t o 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION). (g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery. (7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer t o 5 - BRAKES - STANDARD PROCE-
DURE). (8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 45). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
For information on master cylinder application,
bore and type, view the following table:
BRAKE SYSTEM MASTER CYLINDER
BORE/TYPE
Disc/Drum - ABS 23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Drum - Non-ABS 23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Disc - ABS 25.4 mm (1.0 in.)
Conventional
Compensating Port
Disc/Disc ABS With
Traction Control 25.4 mm (1.0 in.) Dual
Center Port
Fig. 44 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
Fig. 45 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RS BRAKES5s-33
JUNCTION BLOCK (Continued)

CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections. The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir. The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 46). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly. The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.
(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358. (2) Attach special tools for bleeding master cylin-
der in the following fashion: (a)For non-traction control equipped mas-
ter cylinders , thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 47). (b) For traction control equipped master
cylinders , thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 47).
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level. (3) Fill brake fluid reservoir with Mopar tbrake
fluid or equivalent conforming to DOT 3 (DOT 4 and
DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
Fig. 46 RHD MASTER CYLINDER AND POWER BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
5s - 34 BRAKESRS
MASTER CYLINDER (Continued)

(2) Remove brake fluid reservoir cap. Using a
syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cylinder assembly from the
power brake vacuum booster. (Refer t o 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER CYL-
INDER - REMOVAL). (4) Mount the master cylinder in a vise using the
master cylinder mounting flange. (5) Using correct size pin punch, remove the two
retaining pins between the fluid reservoir and master
cylinder housing (Fig. 51).
(6) Rock the brake fluid reservoir from side to side
while pulling up to remove it from the seal grommets
in master cylinder housing. (7) Remove the two master cylinder housing to
brake fluid reservoir seal grommets (Fig. 52).
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Install new master cylinder housing to brake
fluid reservoir sealing grommets in master cylinder
housing (Fig. 52). (2) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir. (3) Be sure fluid reservoir is positioned properly on
master cylinder. Bottom of fluid reservoir is to be touching the top of both sealing grommets
when properly installed on master cylinder
housing.
(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 51). (5) Install the master cylinder assembly on the
power brake booster. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER CYLINDER -
INSTALLATION) (6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION
INSTALLATION - LHD
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. 49). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
Fig. 51 Fluid Reservoir Retaining Pins (Typical)
1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER
Fig. 52 Master Cylinder To Fluid Reservoir Seal Grommets
1 - SEAL GROMMETS
2 - MASTER CYLINDER
RS BRAKES5s-37
MASTER CYLINDER (Continued)

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.
48). 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.
48). (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 Mopar t
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. 50). 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.
50). 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.
46). (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 Mopar t
Brake Fluid or equivalent. (11) Road test vehicle to ensure proper operation of
brakes.
PEDALS - ADJUSTABLE
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Move driver's seat to full rearward position.
(2) Disconnect negative battery cable from battery
post and isolate. (3) Remove throttle cable from throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL) (4) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 53). (5) Disconnect parking brake release link at
release handle. (6) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate. (7) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 53). (8) Remove hood release from lower left reinforce-
ment. (9) Remove screws securing instrument panel
lower left reinforcement in place, then remove rein-
forcement (Fig. 54). (10) Remove brake lamp switch. Discard original
switch; it must not be reused. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL) (11) Remove upper and lower steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - REMOVAL)
5s - 38 BRAKESRS
MASTER CYLINDER (Continued)

(3) Install two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash panel. Do not fully tighten at this time.
(4) Install four nuts attaching pedals assembly and
power brake booster to dash panel (Fig. 61). (5) Tighten four booster mounting nuts and two
upper mounting bolts to 28 N´m (21 ft. lbs.) torque. (6) Route pedal adjuster cable up and over right
side of pedals assembly and steering column bracket, then down through hole in steering column bracket
as shown (Fig. 60). Attach end of cable to gear box.
(7) Place adjuster cable through loop on right side
of steering column bracket as shown (Fig. 60). (8) Install booster input rod onto brake pedal pin
and install a NEW retaining clip. (9) Connect wiring connector connecting vehicle
wiring harness to pedal wiring harness (Fig. 58). (10) Connect routing clips retaining vehicle wiring
harness to pedal wiring harness (Fig. 58). (11) Install brake lamp switch bracket on pedals
assembly. Tighten mounting nuts to 6 N´m (50 in.
lbs.) torque. (12) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
57). (13) Install steering column onto lower mounting
studs with nuts started, then install column onto
upper mounting studs and install two upper mount-
ing nuts. Tighten upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque. (14) Install column shaft coupling onto intermedi-
ate shaft and install pinch bolt. Make sure rounded
side of intermediate shaft is matched to the curva-
ture of the coupling. Tighten pinch bolt to 28 N´m
(250 in. lbs.) torque. (15) Remove retainer holding steering wheel in
place on steering column. (16) Attach shift cable to bracket on column.
(17) Connect shift cable end to shift lever mecha-
nism pin (Fig. 55). (18) If equipped, connect PRNDL cable to end of
shift lever mechanism pin and column bracket (Fig.
55). (19) Connect column wiring harness connectors (as
equipped) to SKIM, BTSI solenoid, ignition switch,
multi-function switch, and clockspring. (20) Install lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - 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.
(21) Install and adjust NEW brake lamp switch.
(Refer t o 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION) (22) Install instrument panel lower left reinforce-
ment (Fig. 54). (23) Attach hood release to lower left reinforce-
ment.
Fig. 60 Drive Cable Routing
1 - ADJUSTER CABLE
2 - ROUTING LOOP
3 - CABLE ATTACHMENT AT MOTOR
4 - GEAR DRIVE
5 - CABLE ATTACHMENT AT GEAR BOX
6 - STEERING COLUMN BRACKET
Fig. 61 Booster Mounting (Typical)
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
RS BRAKES5s-41
PEDALS - ADJUSTABLE (Continued)

(24) Install knee blocker reinforcement plate (Fig.
53). (25) Connect parking brake release link to release
handle. (26) Install data link diagnostic connector to
mounting hole in reinforcement plate. (27) Install lower steering column cover/knee
blocker (Fig. 53). (28) Install throttle cable onto throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery following special Diagnosis And Testing pro-
cedure. (Refer t o 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING) (30) Test operation of adjustable pedals and all
functions that are steering column operated. If appli-
cable, reset radio and clock. (31) Road test the vehicle to ensure proper opera-
tion of steering and brake systems.
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. 62). 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.
63). (6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 63). (7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
Fig. 62 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
Fig. 63 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
5s - 42 BRAKESRS
PEDALS - ADJUSTABLE (Continued)

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.). (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. 62).
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 t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer t o 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. 64).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
All Left-Hand-Drive (LHD) vehicles use a 270 mm
single diaphragm vacuum power brake booster. All
Right-Hand-Drive (RHD) vehicles use a 225/200 mm
tandem diaphragm vacuum 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. The power brake booster can be identified by the
tag attached to the body of the booster (Fig. 65). This
tag contains the production part number, the date it
was built, and who the manufacturer of the power
brake booster is.
Fig. 64 Power Brake Booster (Typical)
1 - VACUUM CHECK VALVE
2 - POWER BRAKE BOOSTER ASSEMBLY
3 - INPUT ROD
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - OUTPUT ROD
RS BRAKES5s-43
PEDAL TORQUE SHAFT - RHD (Continued)