2004 CHRYSLER VOYAGER 8e electrical

(Fig. 12). The ICU is located below the master cylin-
der in the engine compartment (Fig. 13).
Two different ICU's (HCU and CAB) are used on
this vehicle depending on whether or not the vehicle
is equipped with traction control. The HCU on a
vehicle equipped with traction control has a valve
block that is approximately one inch longer than a
HCU on a vehicle that is equipped with ABS only.
The ABS-only ICU consists of the following compo-
nents: the CAB, eight (build/decay) solenoid valves
(four inlet valves and four outlet valves), valve block,
fluid accumulators, a pump, and an electric motor.
The ABS-with traction control ICU consists of the
following components: the CAB, eight (build/decay)solenoid valves (four inlet valves and four outlet
valves), two traction control (ASR) valves, two
hydraulic shuttle valves, valve block, fluid accumula-
tors, a pump, and an electric motor.
The replaceable components of the ICU are the
HCU and the CAB. No attempt should be made to
service any individual components of the HCU or
CAB. For information on the CAB, (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/CONTROLLER ANTILOCK BRAKE -
DESCRIPTION).
OPERATION
For information of the ICU, refer to these individ-
ual components of the ICU:
²CONTROLLER ANTILOCK BRAKE (CAB)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/CONTROLLER ANTILOCK
BRAKE - OPERATION)
²HYDRAULIC CONTROL UNIT (HCU) (Refer to
5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
HCU (HYDRAULIC CONTROL UNIT) - OPERA-
TION)
For information on the ICU's hydraulic circuits,
refer to HYDRAULIC CIRCUITS AND VALVE
OPERATION. (Refer to 5 - BRAKES - ABS/HY-
DRAULIC/MECHANICAL - OPERATION)
REMOVAL
REMOVAL - LHD
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Remove the battery shield.
(3) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(4) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(5) Remove the screw securing the engine coolant
filler neck to the battery tray.
(6) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(7) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder once the
brake tubes are removed from the HCU.
CAUTION: Do not apply a 12±volt power source to
any terminals of the 24-way CAB connector when
disconnected.
(8) Disconnect the wiring harness connector from
the speed control servo.
(9) Remove the speed control servo mounting nuts
and move the servo out of the way.
Fig. 12 INTEGRATED CONTROL UNIT (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
Fig. 13 ICU LOCATION IN VEHICLE
1 - POWER BRAKE BOOSTER
2 - MASTER CYLINDER
3 - ICU
5 - 90 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

INSTALLATION - PARKING BRAKE CABLE(INTERMEDIATE) ......................66
INSTALLATION - PARKING BRAKE CABLE (RIGHT REAR) ........................66
INSTALLATION - PARKING BRAKE CABLE (LEFT REAR) .........................66
ADJUSTMENTS ADJUSTMENT - PARKING BRAKE CABLES . 66
CABLES - PARKING BRAKE (EXPORT) REMOVAL - FRONT CABLE ...............67
INSTALLATION - FRONT CABLE ............67
LEVER - PARKING BRAKE REMOVAL .............................67 INSTALLATION
.........................67
LEVER - PARKING BRAKE (EXPORT) REMOVAL - PARKING BRAKE LEVER ANDFRONT CABLE .......................68
INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE ...................69
SHOES - PARKING BRAKE REMOVAL .............................69
INSTALLATION .........................75
ADJUSTMENTS ADJUSTMENT - PARKING BRAKE SHOES . . 76
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components: ² Brake pedal
² Power brake booster
² Master cylinder
² Brake tubes and hoses
² Proportioning valve (non-ABS vehicles only)
² Disc brakes
² Drum brakes
² Brake lamp switch
² Brake fluid level switch
² Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options. The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other. For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION) Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.
DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly. The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
come in contact with a hub mounted drum (drum for
disc/drum brakes or drum-in-hat for disc/disc brakes)
and hold it in place.
WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
RS BRAKES5s-3

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)

(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.
Do not move the pedal once the pressure is applied
or the test results may vary. (7) Have an assistant reattach the vacuum line
pliers to the vacuum supply hose. (8) Allow 5 seconds for stabilization, then observe
the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective. (9) Remove the pliers and vacuum gauge.
REMOVAL
REMOVAL - LHD
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes). (2) Remove negative battery cable terminal from
battery. (3) Remove positive battery cable terminal from
battery. (4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray. (6) Remove screw securing engine coolant filler
tube to battery tray. (7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray. (8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray. (9) If vehicle is equipped with speed control:(a) Disconnect wiring harness connector from
the speed control servo. (b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL) (11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 66).
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(12) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as Mopar tBrake Parts Cleaner or equivalent.
(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 67). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to
power brake booster (Fig. 67). (15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
Fig. 66 Master Cylinder And Booster
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
RS BRAKES5s-45
POWER BRAKE BOOSTER (Continued)

INSTALLATION
INSTALLATION - LHD
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 70).
It may be necessary to push in on booster input rod
as it is guided through the dash panel. (2) Install the four nuts mounting the booster to
the dash panel (Fig. 69). Tighten the mounting nuts
to a torque of 29 N´m (250 in. lbs.). (3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 76).
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.
(5) 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) (6) Install the silencer panel below the steering
column. (7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange. (9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 77).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston. (11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 67). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.). (12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 66). (13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 67).
Tighten the tube nuts to 17 N´m (145 in lbs.). (14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION) (15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
Fig. 76 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
Fig. 77 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
RS BRAKES5s-49
POWER BRAKE BOOSTER (Continued)