2004 CHRYSLER VOYAGER brakes

STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RELEASE
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables. This parking brake lever (pedal) mechanism is
designed so that the adjuster mechanism will rotate
only half a turn when the tension is released from
the parking brake cable. This eliminates the require-
ment to lock out the automatic adjuster when servic-
ing the parking brake lever (pedal) mechanism and
cables. Use the following procedure to release the tension
from the parking brake cables and the automatic
adjuster in the parking brake lever (pedal) mecha-
nism. (1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 95).
(2) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 96). (3) Remove the equalizer from the front parking
brake cable. (4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever (pedal) mechanism to rotate
around to its stop. This will remove the tension from
the adjuster and front park brake cable (Refer to 5 -
BRAKES/PARKING BRAKE - STANDARD PROCE-
DURE).
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RESET
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables. (1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 95). (2) Install the equalizer on the front parking brake
cable. (3) Install the left rear and intermediate park
brake cable in the correct location on the parking
brake cable equalizer (Fig. 96). (4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever (pedal) mechanism to tension the
park brake cables. (5) Apply and release the parking brake lever
(pedal) one time. This will seat the parking brake
cables and allow the auto adjuster in the parking
brake lever (pedal) mechanism to correctly tension
the parking brake cables.
Fig. 95 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 96 Parking Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
RS BRAKES5s-61
PARKING BRAKE (Continued)

CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE (FRONT)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES - STANDARD PRO-
CEDURE). (3) Remove the intermediate and left rear park
brake cable from the park brake cable equalizer (Fig.
97).
(4) Remove the front park cable housing retainer
from body outrigger bracket (Fig. 98). Cable is
removable by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver. (5) Lower vehicle.
(6) Remove the left front door sill molding.
(7) Remove the left front kick panel for access to
the park brake cable and park brake pedal assembly. (8) Lift floor mat for access to park brake cable
and floor pan. Pull the seal and the park brake cable
(Fig. 99) out of the floor pan of vehicle. (9) Pull parking brake cable strand end forward
and disconnect button from clevis. Tap cable housing
end fitting out of pedal assembly bracket. (10) Remove cable retainer from the parking brake
lever (pedal) assembly bracket. (11) Pull front parking brake cable assembly out of
vehicle through hole in floor pan.
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (2) Manually lock out the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
Fig. 97 Park Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 98 Front Park Brake Cable Attachment To Body
1 - CABLE HOUSING RETAINER
2 - BODY OUTRIGGER BRACKET
3 - PUSH WRENCH OVER END OF RETAINER HERE
4 - FRONT PARK BRAKE CABLE
Fig. 99 Front Park Brake Cable At Floor Pan
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5s - 62 BRAKESRS

izer, do not remove the locking pliers until
reinstallation of the cable is complete.(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 100).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 100). (5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 101). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 101).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
REMOVAL - PARKING BRAKE CABLE (RIGHT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in the rear parking brake cables
by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 102).
(5) Disconnect the right rear parking brake cable
from the connector on the intermediate cable (Fig.
103). (6) To remove the right parking brake cable hous-
ing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers (Fig. 104). The alternate method
using an aircraft type hose clamp will not work on
the right side of the vehicle. (7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
Fig. 100 Parking Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 101 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 102 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RS BRAKES5s-63
CABLES - PARKING BRAKE (Continued)

(8) Disconnect parking brake cable from parking
brake actuator lever. (9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 105).
Remove the cable.
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly. (3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in rear park brake cables by lock-
ing out the automatic adjuster as described here.
Grasp an exposed section of front park brake cable
near the equalizer and pull down on it. Then install
a pair of locking pliers on the cable just rearward of
the second body outrigger bracket (Fig. 106).
(5) Disconnect the left rear parking brake cable
from the parking brake cable equalizer (Fig. 107).
Fig. 103 Right Rear Cable Connection To Intermediate Cable
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 104 Right Park Brake Cable Removal From Body Bracket
1 - RIGHT REAR BODY BRACKET
2 - PARK BRAKE CABLE
3 - 14MM WRENCH
4 - LEAF SPRING AND BRACKET
Fig. 105 Removing Park Brake Cable From Brake Support Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 106 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
5s - 64 BRAKESRS
CABLES - PARKING BRAKE (Continued)

(6) To remove parking brake cable housing from
the body bracket, slide a 14 mm box end wrench over
retainer end compressing the three fingers (Fig. 108).
Alternate method is to use an aircraft type hose
clamp.
(7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL). (8) Disconnect parking brake cable from parking
brake actuator lever. (9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 109).
INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)
(1) Pass front parking brake cable assembly
through hole in floor pan from the inside of the vehi-
cle. (2) Pass cable strand button through the hole in
the lever (pedal) assembly bracket. (3) Install cable retainer onto the park brake cable
and then install cable retainer into pedal assembly
bracket. (4) Install the end of the park brake cable into the
retainer previously installed into the park brake
pedal bracket. (5) Install cable strand button into the clevis on
the park brake pedal mechanism. (6) Install the front park brake cable floor pan seal
into hole in floor pan. Seal is to be installed so the
flange on the seal is flush with the floor pan (Fig.
99). Fold carpeting back down on floor. (7) Raise vehicle.
(8) Insert brake cable and housing into body out-
rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 98). (9) Manually reset the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES - STANDARD PRO-
CEDURE).
Fig. 107 Parking Brake Cables At Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 108 Parking Brake Cable Removal From Body Bracket
1 - LEFT REAR PARK BRAKE CABLE
2 - BODY BRACKET
3 - LEAF SPRING MOUNTING BRACKET
4 - CABLE RETAINER
5 - 14MM BOX WRENCH
Fig. 109 Removing Parking Brake Cable From BrakeSupport Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
RS BRAKES5s-65
CABLES - PARKING BRAKE (Continued)

(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 97). (11) Lower vehicle and apply the park brake pedal
1 time. This will seat the parking brake cables.
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets. (2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 100) (Fig. 101). (3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION). (4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 101). (5) Install the intermediate park brake cable on
the cable equalizer (Fig. 100). (6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables. (7) Install and position the foam collar on the
parking brake cable to prevent it from rattling
against the vehicle's floor. (8) Lower the vehicle and apply the park brake
pedal 1 time, this will seat the park brake cables.
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place. (2) Attach the parking brake cable onto the park-
ing brake actuator lever. (3) Install the brake shoes on the rear brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place. (5) Connect the right rear parking brake cable to
the connector on the intermediate parking brake
cable (Fig. 103). (6) Install the brake drum, then the wheel and tire
assembly. (7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables. (8) Lower the vehicle. (9) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place. (2) Attach the parking brake cable onto the park
brake actuator lever. (3) Install the brake shoes on the rear brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place. (5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 107). (6) Install brake drum, and wheel and tire assem-
bly. (7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables. (8) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag. Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. (Refer t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer t o 5 - BRAKES/PARKING
BRAKE/SHOES - ADJUSTMENTS). When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes. When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
5s - 66 BRAKESRS
CABLES - PARKING BRAKE (Continued)

CABLES - PARKING BRAKE
(EXPORT)
REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE
(Refer t o 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE). (2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal. (3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel. (6) Remove the steering column cover from the
lower instrument panel. (7) Remove the reinforcement from the lower
instrument panel. (8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 110).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable. (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. 111). (12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 111). (13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 111).
(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.
111). (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.Fig. 110 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 111 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RS BRAKES5s-67

(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. 111). (8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 111). (9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 111). (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. 110).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer t o 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 the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 112).
(3) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 113).
(4) Remove the equalizer from the front parking
brake cable. (5) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever mechanism to rotate around to
its stop and remove the tension from the adjuster
and front park brake cable.
Fig. 112 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 113 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5s - 68 BRAKESRS
LEVER - PARKING BRAKE (Continued)