2004 CHRYSLER VOYAGER weight

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.
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove both front wheel and tire assemblies.
(3) Begin on one side of the vehicle.
(4) Remove the anti-rattle clip from the outboard
side of the caliper and adapter.
(5) Remove the two caliper guide pin bolts.
(6) Remove caliper from caliper adapter and brake
rotor.
CAUTION: Supporting weight of caliper by the flex-
ible brake fluid hose can damage the hose.
(7) Using wire or cord, hang the caliper from the
front strut assembly (Fig. 12). Support the caliper
Fig. 11 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
5 - 14 BRAKES - BASERS
HYDRAULIC/MECHANICAL (Continued)

firmly to prevent weight of caliper from being sup-
ported by the brake fluid hose.
(8) Remove the outboard brake shoe from the cali-
per adapter.
(9) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip on shoe is free
from the cavity in the caliper piston (Fig. 13).
(10) Repeat the above procedure on other side of
the vehicle.REMOVAL - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
NOTE: Perform Step 2 through Step 5 on each side
of the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 14).
(4) Remove the disc brake caliper from the disc
brake adapter and hang out of the way using wire or
a bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove the brake shoes from the disc brake
caliper adapter.
Fig. 12 Stored Front Disc Brake Caliper
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
Fig. 13 Removing Inboard Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
Fig. 14 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
RSBRAKES - BASE5-15
BRAKE PADS/SHOES - FRONT (Continued)

tightening sequence to the full specified torque of 135
N´m (100 ft. lbs.).
(13) Lower vehicle.
(14) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(15) Check and adjust brake fluid level as neces-
sary.
(16) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
NOTE: Perform steps Step 1 through Step 5on each
side of the vehicle.
(1) Place the brake shoes in the adapter anti-rattle
clips.
(2) Completely retract the caliper piston back into
the bore of the caliper.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(3) Install the disc brake caliper over the brake
shoes on the brake caliper adapter.
(4) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N´m (26 ft. lbs.) (Fig.
14).
(5) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N´m (100
ft. lbs.).
(6) Lower the vehicle.
(7) Pump the brake pedal several times. This will
set the shoes to the brake rotor.
(8) Check and adjust the brake fluid level as nec-
essary.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoes.
BRAKE PADS/SHOES - REAR
DISC
REMOVAL - REAR DISC BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 15).(4) 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. 16).
(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
17).
(6) If the brake rotor needs to be removed it can be
removed by removing the retainer clips and then
pulling the rotor straight off the wheel mounting
studs.
Fig. 15 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 16 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
RSBRAKES - BASE5-17
BRAKE PADS/SHOES - FRONT (Continued)

(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 110).
(10) Remove rear caliper from adapter using the
following 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. 111).(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
112).
Fig. 109 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 110 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 111 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
Fig. 112 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
5 - 68 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (2) Remove both front wheel and tire assemblies.
(3) Begin on one side of the vehicle.
(4) Remove the anti-rattle clip from the outboard
side of the caliper and adapter. (5) Remove the two caliper guide pin bolts.
(6) Remove caliper from caliper adapter and brake
rotor.
CAUTION: Supporting weight of caliper by the flex-
ible brake fluid hose can damage the hose.
(7) Using wire or cord, hang the caliper from the
front strut assembly (Fig. 11). Support the caliper
firmly to prevent weight of caliper from being sup-
ported by the brake fluid hose.
(8) Remove the outboard brake shoe from the cali-
per adapter. (9) Pull the inboard brake shoe away from the cal-
iper piston until the retaining clip on shoe is free
from the cavity in the caliper piston (Fig. 12). (10) Repeat the above procedure on other side of
the vehicle.
REMOVAL - FRONT DISC BRAKE SHOES (TRW
BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
NOTE: Perform Step 2 through Step 5 on each side
of the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 13).
Fig. 11 Stored Front Disc Brake Caliper
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
Fig. 12 Removing Inboard Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
Fig. 13 Brake Caliper Mounting (Typical)
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5s - 14 BRAKESRS

(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
16).
(6) If the brake rotor needs to be removed it can be
removed by removing the retainer clips and then
pulling the rotor straight off the wheel mounting
studs. (7) Remove the outboard brake shoe from the cali-
per. Brake shoe is removed by pushing the shoe
toward the piston, disengaging the two metal protru-
sions on the shoe back, then sliding the brake shoe
off the caliper. (8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 17).
CLEANING - DISC BRAKE SHOES
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.
INSPECTION - DISC BRAKE SHOES
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora-
tion. Check the clearance between the tips of the
wear indicators on the shoes (if equipped) and the
brake rotors. If a visual inspection does not adequately deter-
mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake
shoe and its lining material thickness should be mea-
sured at its thinnest point. ² For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced. ² For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced. ² Typically, if front shoes are worn out, both fronts
and rears need to be replaced. Make sure to check
rears.
Fig. 16 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 17 Removing Inboard Brake Shoe
1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
3 - CALIPER ASSEMBLY
4 - RETAINING CLIP
5 - PISTON
RS BRAKES5s-17
BRAKE PADS/SHOES - REAR DISC (Continued)

(10) Remove rear caliper from adapter using the
following 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. 119).
(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
120).
(12) Remove the rotor from the hub/bearing.
(13) Remove the park brake cable mounting bolt to
adapter. (14) Remove the end of the park brake cable from
the actuator lever on the adapter (Fig. 121).
(15) Remove the end of the park brake cable from
the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in (Fig. 122) to com-
press the locking tabs on the park brake cable
retainer.
Fig. 119 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
Fig. 120 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 121 Park Brake Cable Attachment To Actuator
1 - ADAPTER
2 - PARK BRAKE CABLE
3 - ACTUATOR
4 - AXLE
5 - DRIVESHAFT
6 - PARK BRAKE CABLE RETAINER
7 - HORSESHOE CLIP
Fig. 122 Park Brake Cable Removal From Adapter
1 - DRIVESHAFT
2 - 1/2º WRENCH
3 - PARK BRAKE CABLE
4 - PARK BRAKE CABLE RETAINER
5 - ADAPTER
RS BRAKES5s-71
SHOES - PARKING BRAKE (Continued)

HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 13).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
Fig. 12 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP SWITCH (Continued)