2004 CHRYSLER VOYAGER Power system

CAUTION
CAUTIONS
The ABS uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.
CAUTION: In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so for a diagnostic proce-
dure.
CAUTION: These circuits should only be tested
using a high impedance multi-meter or the DRBIIIT
scan tool as described in this section. Power
should never be removed or applied to any control
module with the ignition in the ON position. Before
removing or connecting battery cables, fuses, or
connectors, always turn the ignition to the OFF
position.
CAUTION: The CAB 24-way connector should never
be connected or disconnected with the ignition
switch in the ON position.
CAUTION: This vehicle utilizes active wheel speed
sensors. Do not apply voltage to wheel speed sen-
sors at any time.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of aftermarket electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, etc.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS, do not apply a
12-volt power source to the ground circuit of the
pump motor in the HCU. Doing this will damage the
pump motor and will require replacement of the
entire HCU.
CAUTION: An attempt to remove or disconnect cer-
tain system components may result in improper
system operation. Only those components with
approved removal and installation procedures in
this manual should be serviced.CAUTION: If welding work is to be performed on the
vehicle, using an electric arc welder, the CAB con-
nector should be disconnected during the welding
operation.
CAUTION: Many components of the ABS System
are not serviceable and must be replaced as an
assembly. Do not disassemble any component
which is not designed to be serviced.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surface,
wash off with water immediately.
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING
The base brake's hydraulic system must be bled
anytime air enters the hydraulic system. The ABS
though, particularly the ICU (HCU), should only be
bled when the HCU is replaced or removed from the
vehicle. The ABS must always be bled anytime it is
suspected that the HCU has ingested air. Under
most circumstances that require the bleeding of the
brakes hydraulic system, only the base brake
hydraulic system needs to be bled.
It is important to note that excessive air in the
brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the
brake fluid level remains close to the FULL level in
the master cylinder fluid reservoir. Check the fluid
level periodically during the bleeding procedure and
add DOT 3 brake fluid as required.
The ABS must be bled as two independent braking
systems. The non-ABS portion of the brake system
with ABS is to be bled the same as any non-ABS sys-
tem.
The ABS portion of the brake system must be bled
separately. Use the following procedure to properly
bleed the brake hydraulic system including the ABS.
5 - 78 BRAKES - ABSRS
BRAKES - ABS (Continued)

(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

CONDITION POSSIBLE CAUSES CORRECTION
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT) 1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe support plate where shoes ride. 1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined braking surface. 1. Replace brake drums as necessary.
DRUM BRAKE HOWL OR
MOAN 1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor. 1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING 1. ABS wheel speed sensor or tone
wheel. 1. Inspect, correct or replace faulty
component(s).
SCRAPING (METAL-TO-
METAL). 1. Foreign object interference with
brakes. 1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or disc brake rotor has excessive
thickness variation. 1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL) 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent. 5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY) 1. Parking brake cables binding or
froze up. 1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes. 2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only). 3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted. Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes. Repair source of contamination.
2. Improper power brake booster
assist. 2. Refer to power brake booster
diagnosis and testing.
RS
BRAKES5s-5
BRAKES - BASE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
EFFORT 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist
(vacuum leak). 2. Refer to power brake booster
diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor. 4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK) 1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.
2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING) 1. One of the two hydraulic circuits
to the front brakes is malfunctioning.
1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation. 1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes. 2. Power brake booster runout
(vacuum assist). 2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles). 2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist. 3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N 1. Brake lamp switch out of
adjustment. 1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely. 4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes. Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
5s - 6 BRAKESRS
BRAKES - BASE (Continued)

PRESSURE BLEEDING PROCEDURE
CAUTION: Use bleeder tank Special Tool C-3496-B
or equivalent with Adapter, Special Tool 6921, to
pressurize the hydraulic system for bleeding.Follow pressure bleeder manufacturer's instruc-
tions for use of pressure bleeding equipment. (1) Install the Adapter Master Cylinder Pressure
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 2). Attach the fluid hose
from the pressure bleeder to the fitting on Special
Tool 6921.
(2) Attach a clear plastic hose to the bleeder screw
at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid. (3) Open the left rear wheel bleeder screw at least
one full turn or more to obtain an adequate flow of
brake fluid.
CAUTION: ªJust crackingº the bleeder screw often
restricts fluid flow, allowing only a slow, weak fluid
discharge of fluid. This practice will NOT get all the
air out. Make sure the bleeder is opened at least 1
full turn when bleeding.
(4) After 4 to 8 ounces of brake fluid has been bled
through the hydraulic system, and an air-free flow is
maintained in the hose and jar, this will indicate a
good bleed of the hydraulic system has been
obtained. (5) Repeat the procedure at all the other remain-
ing bleeder screws. (6) Check pedal travel. If pedal travel is excessive
or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not
enter the brake system through the master cylinder.
(7) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
SPECIFICATIONS
BRAKE FASTENER TORQUE
DESCRIPTION N´m Ft.
Lbs. In.
Lbs.
ABS ICU Mounting Bolts To
Bracket 11 Ð 9 7
ABS ICU Mounting
Bracket-To-Cradle Bolts 28 21 250
ABS CAB-To-HCU Mounting
Screws 2Ð17
ABS Wheel Speed Sensor
Head Mounting Bolt - Front 13 Ð 115
ABS Wheel Speed Sensor
Head Mounting Bolt - Rear 10 Ð 90
Adjustable Pedal Position
Sensor Mounting Screws 7.5 66 Ð
Adjustable Pedal Module
Mounting Screws 2.0 15 Ð
Brake Tube Nuts 17 Ð 145
Brake Hose Intermediate
Bracket Bolt 12 Ð 105
Brake Hose-To-Caliper
Mounting Bolt 47 35 Ð
Disc Brake Caliper Guide
Pin Bolts 35 26 Ð
Disc Brake Caliper Bleeder
Screw 15 Ð 125
Drum Brake Wheel Cylinder
Mounting Bolts 8Ð75
Drum Brake Wheel Cylinder
Mounting Bleeder screw 10 Ð 80
Drum Brake Support Plate
Mounting Bolts 130 95 Ð
Junction Block (Non-ABS
Brakes) Mounting Bolts 28 21 250
Master Cylinder Mounting
Nuts 25 19 225
Power Brake Booster
Mounting Nuts 28 21 250
Fig. 2 Tool 6921 Installed On Master Cylinder
1 - SPECIAL TOOL 6921
2 - FLUID RESERVOIR
5s - 8 BRAKESRS
BRAKES - BASE (Continued)

line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 3).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch. (3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir. (2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 3).
ADJUSTABLE PEDALS
SWITCH
REMOVAL
(1) Remove steering column lower shroud. (Refer
to 19 - STEERING/COLUMN/LOWER SHROUD -
REMOVAL) (2) Depress retaining tabs on top and bottom of
switch and remove switch from lower shroud.
INSTALLATION
(1) Install the switch into the lower shroud, snap-
ping it into place. (2) Connect wiring harness connector to switch,
then install lower shroud on steering column. (Refer
to 19 - STEERING/COLUMN/LOWER SHROUD -
INSTALLATION) (3) Ensure proper operation of adjustable pedals.
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
Each front disc brake consists of the following com-
ponents: ² Brake Rotor
² Brake Caliper
² Brake Caliper Adapter
² Shoes (Pads)
There are two non-interchangeable front disc brake
systems. One is manufactured by TRW and the other
by Continental Teves.
CAUTION: Components used on the TRW brakes
are not interchangeable with the Continental Teves
brakes. The two different systems must not be
mixed. Improper performance, noise and increased
stopping distance can occur.
The TRW front brake caliper is a one piece casting
containing a single 64 mm diameter piston bore (Fig.
4) with a phenolic piston. The caliper mounts to a
caliper adapter using two guide pin bolts that thread
into guide pins slid into the caliper adapter (Fig. 5).
The pins are lubricated and have boots that seal
them in place in the adapter. The Continental Teves front brake caliper is a one
piece casting containing a single piston 66 mm diam-
eter bore (Fig. 4) with a phenolic piston. The caliper
mounts to a caliper adapter using two guide pin bolts
that thread into the caliper adapter and slide on
bushings mounted in the caliper.
CAUTION: TRW and Continental Teves calipers are
not interchangeable. Each caliper is specifically
designed for the unique brake system. If calipers
are interchanged, improper performance, noise and
increased stopping distance can occur.
Fig. 3 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
5s - 10 BRAKESRS
BRAKE FLUID LEVEL SWITCH (Continued)

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)