2004 CHRYSLER VOYAGER wheel

(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer t o 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION) (4) Install the rear park brake cable into its
mounting hole in the rear brake support plate. (5) Install the park brake cable on the park brake
actuation lever. (6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate. (7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup- port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(8) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque. (9) Install the rear brake shoes on the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (10) Install brake drum.
(11) 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.). (12) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS) (13) Remove brake pedal depressor tool.
(14) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE). (15) Lower the vehicle.
WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends (5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL) (7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate. (8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
Fig. 92 Removing Park Brake Cable From Brake Support Plate
1 - PARK BRAKE CABLE
2 - CABLE RETAINER
3 - 14 mm BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 93 Brake Support Plate Mounted On BearingAttaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
RS BRAKES5s-59
SUPPORT PLATE - DRUM BRAKE (Continued)

If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate. (2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque. (3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque. (4) Install the rear brake shoes on the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.). (7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS) (8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE). (10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 94). It is a automatic-adjust-
ing type lever. The vehicle has four flexible steel parking brake
cables. They are: ² Front
² Intermediate
² Left rear
² Right rear
The front parking brake cable extends from the
parking brake lever. A steel equalizer bracket con-
nects the front parking brake cable to the left rear
and intermediate cable. The intermediate cable is
connected to the right rear cable using a parking
brake cable connector. On vehicles equipped with rear drum brakes, the
rear service brakes also act as the vehicle's parking
brakes. Vehicles equipped with rear disc brakes use a
small duo-servo brake assembly mounted to the each
rear disc brake caliper adapter as the parking brake.
The inside of the brake rotor (hat section of drum-in-
hat style brake rotor) is used as the parking brake
drum.
DESCRIPTION - EXPORT
The parking brake system on this vehicle features
a hand-operated parking brake lever. The lever is
located between the two front seats and requires a
special front cable.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment. When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel. The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park-
ing brake cables. An equalizer bracket is used at the rear end of the
front parking brake cable to distribute tension
equally to each parking brake cable.
Fig. 94 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5s - 60 BRAKESRS
WHEEL CYLINDERS (Continued)

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)

(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)

(6) Remove the front parking brake cable housing
from body outrigger bracket. Cable is removable by
sliding a 14 mm box wrench over the cable retainer
and compressing the three retaining fingers. Alter-
nate method: Use an aircraft type hose clamp and
screwdriver. (7) Remove the four mounting nuts from the bot-
tom of the parking brake lever bracket. (8) Lower vehicle.
(9) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL) (10) If equipped with a manual transaxle, remove
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- REMOVAL) (11) Unhook the end of the parking brake cable
from the lever mechanism. (12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers. (13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment. (14) Lift the parking brake lever and slide the
parking brake cable out. (15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle. (2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket. (3) Hook the end of the parking brake cable on the
parking brake lever mechanism. (4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan. (5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION) (6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION) (7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place. (9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place. (10) 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.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 113). (12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables. (13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake. The park-
ing brake is set to keep the hub/bearing and
axle shaft from rotating when loosening the
hub nut. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove the wheel and tire assembly.
(4) AWD only - Remove the cotter pin and nut
retainer (Fig. 114) from the stub shaft of the outer
C/V joint.
Fig. 114 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RS BRAKES5s-69
LEVER - PARKING BRAKE (EXPORT) (Continued)

(16) AWD only - Remove ABS wheel speed sensor
head from hub/bearing (Fig. 123).
(17) FWD only - Remove the ABS wheel speed sen-
sor from the hub/bearing in the following fashion: (a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 124). (b) Push up on metal retaining clip (Fig. 124)
until it bottoms. This will release wheel speed sen-
sor head from hub and bearing. While holding
metal clip up, pull back on wheel speed sensor
head removing it from hub and bearing. (c) Remove wheel speed sensor from hub/bear-
ing. (18) Remove the hub/bearing-to-axle mounting
bolts (Fig. 125).
(19) Remove the hub/bearing (Fig. 126).
Fig. 123 Speed Sensor Attaching Bolt (AWD)
1 - ADAPTER
2 - TONE WHEEL
3 - WHEEL SPEED SENSOR
4 - AXLE
5 - BOLT
6 - DRIVESHAFT
Fig. 124 Sensor Connection At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 125 Hub/Bearing Mounting Bolts (AWD Shown)
1 - DRIVESHAFT
2 - MOUNTING BOLTS
3 - AXLE
4 - MOUNTING BOLTS
5 - ADAPTER
Fig. 126 Hub/Bearing Removal/Installation (AWD Shown)
1 - PARK BRAKE BRAKE SHOE
2 - OUTER C/V JOINT
3 - HUB/BEARING
4 - PARK BRAKE BRAKE SHOE
5 - STUB SHAFT
5s - 72 BRAKESRS
SHOES - PARKING BRAKE (Continued)

(27) Remove the hold down spring and pin (Fig.
134) from the trailing park brake shoe.
(28) Remove the trailing park brake shoe from the
adapter. (29) Remove the park brake shoe actuator from
the adapter and inspect for signs of abnormal wear
and binding at the pivot point.
INSTALLATION
(1) Install park brake shoe actuator into adapter.
(2) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (3) Install the hold down spring and pin (Fig. 134)
on the trailing park brake shoe. (4) Install the upper return springs (Fig. 133) on
the trailing park brake shoe. (5) Install the upper return springs on the leading
park brake shoe (Fig. 132). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter. (6) Install the adjuster (Fig. 131) between the
leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the
long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter. (7) Install the hold down spring and pin (Fig. 130)
on the leading park brake shoe. (8) Install the lower return spring (Fig. 129) on
the leading and trailing park brake shoes. When
installing the return spring, it is to be installed
behind the park brake shoes (Fig. 129). (9) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle. (10) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 135).
(11) Install the hub/bearing on the stub shaft of
outer C/V joint (AWD only) and into the end of the
axle. (Fig. 126). (12) In a progressive crisscross pattern, tighten
the 4 hub/bearing mounting bolts until the hub/bear-
ing is squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129
N´m (95 ft. lbs.). (13) AWD only - Install the wheel speed sensor on
the hub/bearing and adapter. Install the wheel speed
sensor attaching bolt (Fig. 123). Tighten the wheel
speed sensor attaching bolt to a torque of 12 N´m
(105 in. lbs). (14) FWD only - Install the wheel speed sensor in
the following fashion: (a) If metal wheel speed sensor retaining clip is
not in the neutral installed position on hub and
bearing cap, install from the bottom, if necessary,
and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
Fig. 134 Trailing Brake Shoe Hold Down Pin And Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - TRAILING PARK BRAKE SHOE
5 - ALLEN WRENCH
Fig. 135 Adapter Installed On Mounting Bolts (AWD Shown)
1 - DRIVESHAFT OUTER C/V JOINT
2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
RS BRAKES5s-75
SHOES - PARKING BRAKE (Continued)