2004 CHRYSLER VOYAGER tire pressure

ABS PRIMARY HYDRAULIC CIRCUIT AND
SOLENOID VALVE FUNCTION (ABS WITHOUT
TRACTION CONTROL)
The hydraulic diagram (Fig. 7) shows the vehicle in
the ABS braking mode. The diagram shows one
wheel is slipping because the driver is attempting to
stop the vehicle at a faster rate than is allowed by
the surface on which the tires are riding.²The normally open and normally closed valves
modulate (build/decay) the brake hydraulic pressure
as required.
²The pump/motor is switched on so that the
brake fluid from the low pressure accumulators is
returned to the master cylinder circuits.
²The brake fluid is routed to either the master
cylinder or the wheel brake depending on the posi-
tion of the normally open valve.
Fig. 7 ABS Without Traction Control - Primary Hydraulic Circuit
1 - OUTLET VALVE
2 - PUMP PISTON
3 - PUMP MOTOR (ON)
4 - LOW PRESSURE ACCUMULATOR PRESSURE
5 - LOW PRESSURE ACCUMULATOR
6 - NORMALLY CLOSED VALVE (MODULATING)
7 - TO RIGHT FRONT WHEEL8 - NORMALLY OPEN VALVE (MODULATING)
9 - FROM MASTER CYLINDER
10 - MASTER CYLINDER PRESSURE
11 - CONTROLLED WHEEL PRESSURE
12 - PUMP INTERSTAGE PRESSURE
13 - NOISE DAMPER CHAMBER
5 - 84 BRAKES - ABSRS
HYDRAULIC/MECHANICAL (Continued)

ABS SECONDARY HYDRAULIC CIRCUIT AND
SOLENOID VALVE FUNCTION (ABS WITHOUT
TRACTION CONTROL)
The hydraulic diagram (Fig. 8) shows the vehicle in
the ABS braking mode. The diagram shows one
wheel is slipping because the driver is attempting to
stop the vehicle at a faster rate than is allowed by
the surface on which the tires are riding.
²The normally open and normally closed valves
modulate (build/decay) the brake hydraulic pressure
as required.²The pump/motor is switched on so that the
brake fluid from the low pressure accumulators is
returned to the master cylinder circuits.
²The brake fluid will then be routed to either the
master cylinder or the wheel brake depending on the
position of the normally open valve.
²In the secondary circuit, 1.2 cc brake fluid is
taken in by the lip seal saver to protect the lip seals
on the master cylinder piston.
Fig. 8 ABS Without Traction Control - Secondary Hydraulic Circuit
1 - OUTLET VALVE
2 - PUMP PISTON
3 - LOW PRESSURE ACCUMULATOR PRESSURE
4 - TO RIGHT FRONT WHEEL
5 - FROM MASTER CYLINDER6 - MASTER CYLINDER PRESSURE
7 - CONTROLLED WHEEL PRESSURE
8 - PUMP INTERSTAGE PRESSURE
9 - LIP SEAL SAVER (SECONDARY CIRCUIT ONLY)
RSBRAKES - ABS5-85
HYDRAULIC/MECHANICAL (Continued)

ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID
VALVE, AND SHUTTLE VALVE FUNCTION (ABS
WITH TRACTION CONTROL)
The hydraulic diagram (Fig. 10) shows the vehicle
in the ABS braking mode. The diagram shows one
wheel is slipping because the driver is attempting to
stop the vehicle at a faster rate than is allowed by
the surface on which the tires are riding.
²The hydraulic shuttle valve closes upon brake
application so that the pump/motor cannot siphon
brake fluid from the master cylinder.²The normally open and normally closed valves
modulate (build/decay) the brake hydraulic pressure
as required.
²The pump/motor is switched on so that the
brake fluid from the low pressure accumulators is
returned to the master cylinder circuits.
²The brake fluid is routed to either the master
cylinder or the wheel brake depending on the posi-
tion of the normally open valve.
Fig. 10 ABS With Traction Control - ABS Braking Hydraulic Circuit
1 - OUTLET VALVE
2 - PUMP PISTON
3 - PUMP MOTOR (ON)
4 - SUCTION VALVE
5 - LOW PRESSURE ACCUMULATOR
6 - NORMALLY CLOSED VALVE (MODULATING)
7 - TO RIGHT FRONT WHEEL
8 - NORMALLY OPEN VALVE (MODULATING)9 - NORMALLY OPEN ASR VALVE (OFF)
10 - FROM MASTER CYLINDER
11 - HYDRAULIC SHUTTLE VALVE
12 - MASTER CYLINDER PRESSURE
13 - CONTROLLED WHEEL PRESSURE
14 - LOW PRESSURE ACCUMULATOR PRESSURE
15 - PUMP INTERSTAGE PRESSURE
16 - NOISE DAMPER CHAMBER
RSBRAKES - ABS5-87
HYDRAULIC/MECHANICAL (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

OPERATION - DISC BRAKES (REAR)
The rear disc brakes operate similarly to front disc
brakes, however, there are some features that require
different service procedures.
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER
The rear drum brakes on this vehicle automatically
adjust when required during the normal operation of
the vehicle every time the brakes are applied. Use
the following procedure to test the operation of the
automatic adjuster. Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the adjustment hole in each brake support
plate to provide visual access of the brake adjuster
star wheel. To eliminate the condition where maximum adjust-
ment of the rear brake shoes does not allow the auto-
matic adjuster to operate when tested, back the star
wheel off approximately 30 notches. It will be neces-
sary to hold the adjuster lever away from the star
wheel to permit this adjustment. Have the helper apply the brakes. Upon applica-
tion of the brake pedal, the adjuster lever should
move down, turning the adjuster star wheel. Thus, a
definite rotation of the adjuster star wheel can be
observed if the automatic adjuster is working prop-
erly. If one or more adjusters do not function prop-
erly, the respective drum must be removed for
adjuster servicing.
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
The brake tubes are steel with a corrosion-resis-
tant nylon coating applied to the external surfaces.
The flex hoses are made of reinforced rubber with fit-
tings at each end. The primary and secondary brake tubes leading
from the master cylinder to the ABS ICU Hydraulic
Control Unit (HCU) or the non-ABS junction block
have a special flexible section. This flexible section is
required due to cradle movement while the vehicle is
in motion (The ICU and non-ABS junction block are
mounted to the cradle). If replacement of these
lines is necessary, only the original factory
brake line containing the flexible section must
be used .
OPERATION - BRAKE TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle's suspension.
INSPECTION - BRAKE TUBES AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference. The brake tubing should be inspected periodically
for evidence of physical damage or contact with mov-
ing or hot components. The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections must also be inspected. This flexible tub-
ing must be inspected for kinks, fraying and contact
with other components or with the body of the vehi-
cle.
Fig. 10 Caliper Piston Seal Function For Automatic Adjustment
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
RS BRAKES5s-13
HYDRAULIC/MECHANICAL (Continued)

DISC BRAKE CALIPER -
FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES)
(1) Depress the brake pedal past its first inch of
travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
master cylinder from the brake hydraulic system dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove front wheel and tire assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper. There are two washers (one
on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers. (5) Remove the 2 caliper guide pin bolts.
(6) Remove the brake caliper from the adapter.
REMOVAL - FRONT DISC BRAKE CALIPER
(TRW BRAKES)
(1) Using a brake pedal holding tool, depress the
brake pedal past its first one inch of travel and hold
it in this position. This will isolate the master cylin-
der from the brake hydraulic system and will not
allow the brake fluid to drain out of the master cyl-
inder reservoir when the lines are opened. (2) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE. (3) Remove the front tire and wheel assembly.
(4) Remove the banjo bolt connecting the brake
hose to the brake caliper (Fig. 31). There are two
washers (one on each side of the flex hose fitting)
that will come off with the banjo bolt. Discard the
washers. (5) Remove the two brake caliper guide pin bolts
(Fig. 31). (6) Remove the disc brake caliper from the disc
brake adapter.
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (CONTINENTAL TEVES BRAKES)
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING or INSPECTION in
this section. (1) Using your fingers, collapse one side of the rub-
ber guide pin bushing. Pull the guide pin bushing out
the other side of the brake caliper mounting boss. (2) Repeat this procedure on the remaining bush-
ing.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
Fig. 31 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
RS BRAKES5s-23

(1) Depress the brake pedal past its first inch of
travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
master cylinder from the brake hydraulic system dis-
allowing the brake fluid to completely drain out of
the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (3) Remove rear wheel and tire assembly from
vehicle. (4) Remove the banjo bolt connecting the brake
hose to the brake caliper. There are two washers (one
on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers. (5) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 36).
(6) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 37). (7) If the brake rotor requires removal, it can now
be removed by first removing the retainer clips from
the wheel mounting studs, then pulling the rotor
straight off the studs.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper,
clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from
the caliper bore is to use the hydraulic pressure of
the vehicle's brake system.
(1) Following the removal procedure in DISC
BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of
wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydrauli-
cally push piston out of its bore. Once completed,
apply and hold down the brake pedal to any position
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the
master cylinder reservoir from completely draining
out. (3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws. (5) Remove the piston dust boot from the caliper
and discard.
Fig. 36 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 37 Removing/Installing Caliper
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
RS BRAKES5s-27
DISC BRAKE CALIPER - REAR (Continued)

CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections. The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir. The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 46). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly. The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.
(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358. (2) Attach special tools for bleeding master cylin-
der in the following fashion: (a)For non-traction control equipped mas-
ter cylinders , thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 47). (b) For traction control equipped master
cylinders , thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 47).
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level. (3) Fill brake fluid reservoir with Mopar tbrake
fluid or equivalent conforming to DOT 3 (DOT 4 and
DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
Fig. 46 RHD MASTER CYLINDER AND POWER BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
5s - 34 BRAKESRS
MASTER CYLINDER (Continued)