2004 CHRYSLER VOYAGER instrument panel

(10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(11) Remove the lower bolt mounting the park
brake pedal to the body (Fig. 103).
(12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 103).
(13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 103).
(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block.
(15) Remove park brake pedal release link from
park brake mechanism.
(16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
103).
(17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism.
(2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket.
(3) Install cable strand button into the clevis on
the park brake pedal mechanism.
(4) Install wiring harness connector on warning
indicator lamp ground switch.(5) Install the park brake release rod on the
release mechanism of the park brake pedal.
(6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle.
(7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 103).
(8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 103).
(9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 103).
(10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.).
(11) Verify that the park brake pedal is in the fully
released (full up) position.
(12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 102).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer to 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism.
(16) Install the electrical junction block on the
instrument panel.
(17) Install the reinforcement on the lower instru-
ment panel.
(18) Install the steering column lower cover on the
lower instrument panel.
(19) Install the silencer panel under the instru-
ment panel.
(20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door.
(22) Install the negative (ground) cable on the bat-
tery.
(23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
Fig. 103 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RSBRAKES - BASE5-65
LEVER - PARKING BRAKE (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)

(12) Disconnect wiring harness connectors (as
equipped) from clockspring, multi-function switch,
SKIM module, ignition switch and BTSI solenoid. (13) If equipped, disconnect PRNDL cable from
shift lever and column bracket (Fig. 55). (14) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 55). (15) Remove pinch side clip, then remove shift
cable from bracket on column. (16) Place front wheels in STRAIGHT-AHEAD
position, then secure steering wheel to column in this
position using appropriate retaining method. (17) Remove pinch bolt securing column coupling
to intermediate shaft (Fig. 56).
(18) Loosen two lower steering column mounting
nuts. (19) Remove two upper steering column mounting
nuts. (20) Remove steering column assembly.
(21) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 57).
Fig. 53 Lower Steering Column Cover And Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 54 Instrument Panel Lower Left Reinforcement
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT
Fig. 55 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE (IF EQUIPPED)
5 - STEERING COLUMN
Fig. 56 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
RS BRAKES5s-39
PEDALS - ADJUSTABLE (Continued)

(22) Remove two nuts securing brake lamp switch
bracket to pedal assembly. Remove bracket. (23) Disconnect wiring connector connecting vehi-
cle wiring harness connector to pedal wiring harness
(Fig. 58).
(24) Unfasten routing clips retaining vehicle wir-
ing harness to pedal wiring harness (Fig. 58). (25) Remove power brake booster input rod from
brake pedal pin by performing following: (a) Position small screwdriver between center
tang on retaining clip and brake pedal pin (Fig.
59). (b) Rotate screwdriver, moving retaining clip
center tang enough to allow it to pass over end of
brake pedal pin, then slide retaining clip off brake
pedal pin. (c) Discard retaining clip. Retaining clip must
not be reused. Install NEW retaining clip
when assembling. (d) Slide booster input rod off pedal pin.
(26) Disconnect pedal adjuster cable at brake
pedal adjustment gear box (Fig. 60). (27) Remove pedal adjuster cable from routing loop
on steering column bracket (Fig. 60), then pull gear
box end of cable upward, out of steering column
bracket, and down right side of pedals assembly. (28) Remove four nuts attaching power brake
booster and pedals assembly to dash panel (Fig. 61). (29) Remove two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash. (30) Disconnect throttle cable retainer at accelera-
tor pedal, then remove cable from pedal. (31) Remove adjustable pedals assembly.
INSTALLATION
(1) Install adjustable pedals assembly under
instrument panel. (2) Attach throttle cable to accelerator pedal using
cable retainer.
Fig. 57 Intermediate Shaft Dash Seal And Silencer Shell
1 - INTERMEDIATE SHAFT
2 - DASH SEAL
3 - SILENCER SHELL
Fig. 58 Wiring Harness Connection
1 - VEHICLE WIRING HARNESS
2 - WIRING CONNECTOR
3 - ROUTING LOOP
Fig. 59 Input Rod Brake Pedal Retaining ClipRemoval
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
5s - 40 BRAKESRS
PEDALS - ADJUSTABLE (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)

(16) Disconnect vacuum hose from check valve
located on vacuum booster. DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER. (17) Inside vehicle, remove silencer panel under
instrument panel below steering column. (18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 68). (19) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin. Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling. (20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 69).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 70).
CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.
Fig. 67 Master Cylinder Mounting
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 68 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
Fig. 69 Booster Mounting
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 70 Booster Removal/Installation
5s - 46 BRAKESRS
POWER BRAKE BOOSTER (Continued)