2004 CHRYSLER VOYAGER brake sensor

(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)

(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)

(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side.
(15) Install the park brake cable into its mounting
hole in the adapter. Be sure all the locking tabs
on the park brake cable retainer are expanded
out to ensure the cable will not pull out of the
adapter. (16) Install the end of the park brake cable on the
park brake actuator lever (Fig. 121). (17) Attach park brake cable to adapter using
mounting bolt. (18) Remove the locking pliers (Fig. 117) from the
front park brake cable. (19) Adjust the park brake drum-in-hat brake
shoes. (Refer t o 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS). (20) Install the rotor on the hub/bearing.
(21) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 119).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(22) Install the caliper guide pin bolts (Fig. 118).
Tighten the guide pin bolts to a torque of 35 N´m (26
ft. lbs.). (23) AWD only - Clean all foreign material off the
threads of the outer C/V joint stub shaft. Install the
washer and hub nut (Fig. 116) on the stub shaft of
the outer C/V joint. (24) AWD only - Set the parking brake.
(25) AWD only - Tighten the hub nut to a torque of
244 N´m (180 ft. lbs.). (26) AWD only - Install the spring washer (Fig.
115) on the stub shaft of the outer C/V joint. (27) AWD only - Install the nut retainer and cotter
pin (Fig. 114) on the stub shaft of the outer C/V joint. (28) Install the wheel and tire assembly. Tighten
the wheel mounting stud 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.). (29) Lower vehicle.
(30) Fully apply and release the park brake pedal
one time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(31) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Raise vehicle.
(2) Remove tire and wheel.
(3) Remove disc brake caliper from caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(4) Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum. (5) Using Brake Shoe Gauge, Special Tool C-3919,
or equivalent, accuratelymeasure the inside diam-
eter of the park brake drum portion of the rotor (Fig.
137). (6) Using a ruler that reads in 64th of an inch,
accurately read the measurement of the inside diam-
eter of the park brake drum from the special tool
(Fig. 138).
Fig. 136 Disc Brake Caliper
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 76 BRAKESRS
SHOES - PARKING BRAKE (Continued)

ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING.......................2
BODY CONTROL MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................5
CONTROLLER ANTILOCK BRAKE
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................6
INSTALLATION..........................6
DATA LINK CONNECTOR
DESCRIPTION..........................6
OPERATION............................7
FRONT CONTROL MODULE
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................7
REMOVAL.............................8
INSTALLATION..........................8
HEATED SEAT MODULE
DESCRIPTION..........................8
OPERATION............................9
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE.............................9
REMOVAL.............................9
INSTALLATION.........................10
MEMORY SEAT/MIRROR MODULE
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - MEMORY
SEAT/MIRROR MODULE................10
REMOVAL.............................10
INSTALLATION.........................10
POWER LIFTGATE CONTROL MODULE
DESCRIPTION.........................10
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION........................11OPERATION - SENSOR RETURN - PCM
INPUT..............................15
OPERATION - DATA BUS COMMUNICATION
RECEIVE - PCM INPUT.................15
OPERATION - IGNITION SENSE - PCM
INPUT..............................15
OPERATION - PCM GROUND............15
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM
OUTPUT - SBEC CONTROLLER..........15
OPERATION - 5 VOLT SUPPLY - PCM
OUTPUT............................15
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES..........15
STANDARD PROCEDURE - PINION
FACTOR SETTING.....................15
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE........................16
REMOVAL
REMOVAL - SBEC CONTROLLER.........16
REMOVAL - NGC CONTROLLER..........17
INSTALLATION
INSTALLATION - SBEC CONTROLLER.....17
INSTALLATION.......................17
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................19
SLIDING DOOR CONTROL MODULE
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
TRANSMISSION CONTROL MODULE
DESCRIPTION.........................20
OPERATION...........................20
STANDARD PROCEDURE
STANDARD PROCEDURE - PINION
FACTOR SETTING.....................23
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE........................23
REMOVAL.............................23
INSTALLATION.........................24
RSELECTRONIC CONTROL MODULES8E-1

(5) Obtain ignition keys to be programmed from
customer (8 keys maximum).
(6) Using the DRB III, erase all ignition keys by
selecting MISCELLANEOUS and ERASE ALL CUR-
RENT IGN. KEYS.
(7) Program all ignition keys.
Learned Key In Ignition - Ignition key transponder
ID is currently programmed in SKIM memory.
BODY CONTROL MODULE
DESCRIPTION
The Body Control Module (BCM) is located in the
passenger compartment, attached to the bulkhead
underneath the left side of the instrument panel.
The BCM utilizes integrated circuitry and informa-
tion carried on the Programmable Communications
Interface (PCI) data bus network along with many
hard wired inputs to monitor many sensor and
switch inputs throughout the vehicle. In response to
those inputs, the internal circuitry and programming
of the BCM allow it to control and integrate many
electronic functions and features of the vehicle
through both hard wired outputs and the transmis-
sion of electronic message outputs to other electronic
modules in the vehicle over the PCI data bus.
OPERATION
The Body Control Module (BCM) supplies vehicle
occupants with visual and audible information and
controls various vehicle functions. To provide and
receive information, the BCM is interfaced to the
vehicle's serial bus communications network, referred
to as the Programmable Communications Interface
(PCI) bus.
This network consists of the;
²Powertrain Control Module (PCM)
²Transmission Control Module (TCM)
²Mechanical Instrument Cluster (MIC)
²Occupant Restraint Controller (ORC)
²Compass/Mini-Trip Computer (CMTC)
²Electronic Vehicle Information Center (EVIC)
²Controller Antilock Brake (CAB)²HVAC Control Module
²Sliding Door Control Modules (driver and pas-
senger side doors)
²Power Liftgate Module (PLG)
²Audio system equipped with RAZ, RBU, RBK,
and RBB radios.
²Side Impact Airbag Control Module (SIACM)
²Memory Seat Module (MSM)
²Sentry Key Immobilizer Module (SKIM)
The BCM is operational when battery power is
supplied to the module.
The BCM provides the following features:
²Power Door Locks
²Automatic Door Locks
²Battery Protection - The BCM will automatically
turn off all exterior lamps after 3 minutes, and all
interior lamps after 15 minutes after the ignition is
turned off, if they are not turned off by the driver.
²Chime Control
²Compass/Mini-Trip support.
²Interior Lighting (Courtesy/Reading Lamps)
²BCM Diagnostic Reporting
²Electronic Liftgate Release (with Power Door
Locks)
²Exterior Lighting
²Headlamp Time Delay (with/without Automatic
Headlamps)
²Illuminated Entry
²Fade to Off Interior Lamps - This feature dims
the interior lighting (courtesy lamps) gradually if the
BCM does not receive any new inputs that would
cause the interior lamps to remain on.
²Pulse Width Modulated Instrument Panel Dim-
ming
²Door Lock Inhibit - This feature disables the
door lock functions if the key is in the ignition and
either front door is ajar. Pressing the Remote Keyless
Entry (RKE) lock/unlock button under these condi-
tions result in normal lock/unlock activation.
The BCM has the ability to LEARN additional fea-
tures in the vehicle, provided the appropriate switch
input and PCI data bus messages are received. Refer
to the LEARNED FEATURES table.
RSELECTRONIC CONTROL MODULES8E-3
ELECTRONIC CONTROL MODULES (Continued)

(6) Remove the screws holding the BCM to the
bulkhead.
(7) Remove the BCM from the mounting bracket.
INSTALLATION
(1) Install the BCM to the mounting bracket.
(2) Install the screws holding the BCM to the
bulkhead.
(3) Connect the five wire connectors to the bottom
of the Body Control Module (BCM).
(4) Install the knee blocker and reinforcement
(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER REINFORCEMENT - INSTALLATION).
(5) Install the lower instrument panel silencer.
(6) Connect the battery negative cable.
(7) Verify proper operation of BCM and its func-
tions.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The controller antilock brake (CAB) is a micropro-
cessor-based device which monitors the antilock
brake system (ABS) during normal braking and con-
trols it when the vehicle is in an ABS stop. The CAB
is mounted to the HCU as part of the integrated con-
trol unit (ICU) (Fig. 1). The CAB uses a 24-way elec-
trical connector on the vehicle wiring harness. The
power source for the CAB is through the ignition
switch in the RUN or ON position. The CAB is on
the PCI bus.
OPERATION
The primary functions of the controller antilock
brake (CAB) are to:
²Monitor the antilock brake system for proper
operation.
²Detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
²Control fluid modulation to the wheel brakes
while the system is in an ABS mode.
²Store diagnostic information.
²Provide communication to the DRBIIItscan tool
while in diagnostic mode.
²Illuminate the amber ABS warning indicator
lamp.
²(With traction control only) Illuminate the TRAC
ON lamp in the message center on the instrument
panel when a traction control event occurs.
²(with traction control only) Illuminate the TRAC
OFF lamp when the amber ABS warning indicator
lamp illuminates.
The CAB constantly monitors the antilock brake
system for proper operation. If the CAB detects a
fault, it will turn on the amber ABS warning indica-
tor lamp and disable the antilock braking system.
The normal base braking system will remain opera-
tional.
NOTE: If the vehicle is equipped with traction con-
trol, the TRAC OFF lamp will illuminate anytime the
amber ABS warning indicator lamp illuminates.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The coils then open and close the valves in the
HCU that modulate brake fluid pressure in some or
all of the hydraulic circuits. The CAB continues to
control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that
monitors the antilock brake system for system faults.
When a fault is detected, the amber ABS warning
indicator lamp is turned on and the fault diagnostic
trouble code (DTC) is then stored in a diagnostic pro-
gram memory. A latched fault will disable certain
system functionality for the current ignition cycle. An
unlatched fault will disable certain system function-
ality until the fault condition disappears. These
DTC's will remain in the CAB memory even after the
ignition has been turned off. The DTC's can be read
and cleared from the CAB memory by a technician
using the DRBIIItscan tool. If not cleared with a
DRBIIItscan tool, the fault occurrence and DTC will
Fig. 1 Integrated Control Unit (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
RSELECTRONIC CONTROL MODULES8E-5
BODY CONTROL MODULE (Continued)

be automatically cleared from the CAB memory after
the identical fault has not been seen during the next
3,500 miles. Drive-off may be required for the amber
ABS warning indicator lamp to go out on the next
ignition cycle.
CAB INPUTS
²Wheel speed sensors (four)
²Brake lamp switch
²Ignition switch
²System and pump voltage
²Ground
²Traction control switch (if equipped)
²Diagnostic communication (PCI)
CAB OUTPUTS
²Amber ABS warning indicator lamp actuation
(via BUS)
²Red BRAKE warning indicator lamp actuation
(via BUS)
²Instrument cluster (MIC) communication (PCI)
²Traction control lamps (if equipped)
²Diagnostic communication (PCI, via BUS)
REMOVAL
(1) Disconnect the battery cables.
(2) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(3) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(4) Remove the screw securing the coolant filler
neck to the battery tray.
(5) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(6) Pull up on the CAB connector lock and discon-
nect the 24±way electrical connector (Fig. 2).
(7) Disconnect the pump/motor connector from the
CAB.
(8) Remove the screws securing the CAB to the
HCU (Fig. 3)
(9) Pull CAB straight forward off HCU.
INSTALLATION
(1) Slide the CAB onto the HCU (Fig. 3).
(2) Install screws securing the CAB to the HCU
(Fig. 3) Tighten the mounting screws to 2 N´m (17 in
lbs).
(3) Reconnect the 24±way wiring connector and
the pump/motor wiring connector. (Fig. 2)
(4) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(5) Install the screw securing the coolant filler
neck to the battery tray.
(6) Reconnect the vacuum hose to the coolant tank
built into the battery tray.(7) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(8) Reconnect the battery cables.
(9) Connect a DRBIIItto the vehicle. Check and
clear any faults, and initialize the system.
DATA LINK CONNECTOR
DESCRIPTION
The data link connector is located inside the vehi-
cle, below instrument panel next to the center col-
umn (Fig. 4).
Fig. 2 CAB Connector Lock
1 - CONNECTOR LOCK
2 - CAB
Fig. 3 CAB Mounting Screws
1 - HCU
2 - MOUNTING SCREWS
3 - CAB
8E - 6 ELECTRONIC CONTROL MODULESRS
CONTROLLER ANTILOCK BRAKE (Continued)