2004 CHRYSLER VOYAGER brake pads

(12) Remove the leading brake shoe assembly to
brake support plate hold down spring and pin (Fig.
27) from the brake shoe. Remove the leading brake
shoe from the brake support plate.
(13) Remove the park brake actuator (Fig. 28)
from the leading brake shoe and transfer to the
replacement brake shoe.INSPECTION - REAR DRUM BRAKE SHOE
LINING
(1) Remove the tire and wheel assembly from the
vehicle (2) Remove the rear brake adjusting hole plug
found in the brake support. (3) Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the
notches on the adjusting screw star wheel. (4) Insert Tool C-3784 into brake adjusting hole
and engage notches of brake adjusting screw star
wheel. Release brake by prying down with adjusting
tool. (5) Remove the rear brake drum from the rear hub
and bearing assembly. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL) (6) Inspect brake lining for wear, shoe alignment,
and or contamination from grease or brake fluid.
INSTALLATION - REAR DRUM BRAKE SHOES
(1) Lubricate the eight shoe contact areas on the
support plate and anchor, (Fig. 29) using the
required special Mopar tBrake Lubricant or equiva-
lent.
(2) Install leading brake shoe on brake support
plate. Install the leading brake shoe hold down
spring and pin (Fig. 27) on the brake shoe. (3) Install the park brake actuator strut (Fig. 30)
on the leading brake shoe. Then install the park
brake actuator lever on the strut (Fig. 30).
Fig. 27 Leading Brake Shoe Hold Down Spring And Pin
1 - PARK BRAKE ACTUATING LEVER
2 - BRAKE SUPPORT PLATE
3 - LEADING BRAKE SHOE
4 - HOLD DOWN SPRING AND PIN
Fig. 28 Park Brake Actuator Plate
1 - RETAINING CLIP
2 - BRAKE SHOE ASSEMBLY
3 - ACTUATOR PLATE
Fig. 29 Brake Support Plate Contact Areas
1 - REAR BRAKE SUPPORT PLATE
RS BRAKES5s-21
BRAKE PADS/SHOES - REAR DRUM (Continued)

(4) Install the automatic adjuster screw on the
leading brake shoe. Then install the trailing brake
shoe on the park brake actuating lever and park
brake actuating strut (Fig. 26). Position trailing
brake shoe on brake support plate. (5) Install the brake shoe hold down pin and
spring on the trailing brake shoe (Fig. 25). (6) Install the brake shoe to brake shoe upper
return spring (Fig. 24).
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 23). If
it is located on a non-threaded area of the adjuster,
the function of the automatic adjuster will be
affected.
(7) Install the tension clip (Fig. 23) attaching the
upper return spring to the automatic adjuster assem-
bly. (8) Install the brake shoe to brake shoe lower
return springs on the brake shoes (Fig. 21) and (Fig.
22). (9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 20). (10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 19). (11) Verify that the automatic adjuster lever has
positive contact with the star wheel on the automatic
adjuster assembly. (12) When all components of both rear brake
assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable. (13) Adjust brake shoes assemblies so as not to
interfere with brake drum installation. (14) Install the rear brake drums on the hubs.
(15) Adjust rear brake shoes.
(16) Install the wheel and tire assembly.
(17) 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.). (18) Lower the vehicle.
(19) Push the parking brake lever (pedal) to the
floor once and release pedal. This will automatically
remove the slack from and correctly adjust the park-
ing brake cables. (20) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE SHOES
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
NOTE: Before raising the vehicle, verify the parking
brake lever is fully released.
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (2) Remove rubber plug from rear brake adjusting
hole in the rear brake support plate. (3) Insert a thin screwdriver through the adjusting
hole in the support plate and against the star wheel
of the adjusting screw. Move handle of the tool down-
ward, rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated. (4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel. Care should be taken so as not to bend
adjusting lever or distort lever spring. (5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag. (6) Repeat the above adjustment at the other rear
wheel. (7) Install the adjusting hole rubber plugs back in
the rear brake support plates. (8) Lower the vehicle.
Fig. 30 Park Brake Components Assembled On Leading Brake Shoe
1 - PARK BRAKE CABLE
2 - LEADING BRAKE SHOE
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER
5 - BRAKE SUPPORT PLATE
5s - 22 BRAKESRS
BRAKE PADS/SHOES - REAR DRUM (Continued)

specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).(8) Lower the vehicle.
(9) Remove the brake pedal depressor (holding)
tool. (10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer t o 5 - BRAKES - STANDARD PROCE-
DURE) (11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
DISC BRAKE CALIPER
ADAPTER
REMOVAL - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (2) Remove front wheel and tire assembly, disc
brake caliper and brake shoes. (Refer t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL) (3) Remove two bolts fastening adapter to steering
knuckle, then remove disc brake caliper adapter.
INSTALLATION - FRONT DISC BRAKE CALIPER
ADAPTER
(1) Place adapter over brake rotor and align
adapter mounting holes to knuckle.
CAUTION: Adapter mounting bolts have a special
Dacromet Tcoating applied to resist corrosion. If
mounting bolts need to be replaced, use only
Mopar Treplacement parts.
(2) Install adapter mounting bolts and tighten to
169 N´m (125 ft. lbs.) torque. (3) Install brake shoes, disc brake caliper and
wheel and tire assembly. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
INSTALLATION) (4) Lower vehicle.
(5) Pump the brake pedal several times to set the
pads to the brake rotor. (6) Check and adjust brake fluid level as neces-
sary.
DISC BRAKE CALIPER GUIDE
PINS
REMOVAL - DISC BRAKE CALIPER GUIDE PINS
(TRW BRAKES)
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE. (2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 42).
(4) Remove the disc brake caliper from the disc
brake caliper adapter and hang it out of the way
using wire or a bungee cord. Use care not to overex-
tend the brake hose when doing this. (5) Remove the guide pins and boots from the
adapter as shown (Fig. 43).
INSTALLATION - DISC BRAKE CALIPER GUIDE
PINS (TRW BRAKES)
(1) Lubricate the guide pins and inside the boots
with the packet supplied with the service kit, Syth-
eso GLK-1 lubricant or equivalent. (2) Install the guide pins and boots in the adapter
as shown (Fig. 43). The boots have grooves built into
their inner lips to fit onto the pins and adapter.
CAUTION: Use care when installing the caliper onto
the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
Fig. 42 Brake Caliper Mounting
1 - BRAKE HOSE
2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
5s - 30 BRAKESRS
DISC BRAKE CALIPER - REAR (Continued)

STANDARD PROCEDURE - BRAKE ROTOR
MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action. If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted on-car brake lathe (Fig. 88), or
replaced.
The use of a hub-mounted on-car brake lathe is
highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehi-
cle's hub and bearing.
NOTE: All rotors have markings for minimum allow-
able thickness cast on an un-machined surface of
the rotor (Fig. 89) (Fig. 90). Minimum thickness
specifications can also be found in the specification
table in this section. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS)
Fig. 86 Checking Hub Runout
1 - HUB SURFACE
2 - SPECIAL TOOL C-3339
3 - SPECIAL TOOL SP-1910
Fig. 87 Index Rotor And Wheel Stud
1 - CHALK MARK
Fig. 88 On-Car Brake Lathe
1 - ON-CAR BRAKE LATHE
Fig. 89 Front Brake Rotor
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
5s - 56 BRAKESRS
ROTOR (Continued)

LIMITS/SPECIFICATIONS
Braking Rotor Rotor ThicknessMinimum Rotor
Thickness Rotor Thickness
Variation Rotor Runout*
Front - TRW 27.87±28.13 mm
1.097-1.107 in. 25.3 mm
0.996 in. 0.009 mm
0.0004 in. 0.075 mm
0.0030 in.
Front - Continental Teves 27.90±28.10 mm
1.098-1.106 in. 25.3 mm
0.996 in. 0.008 mm
0.0003 in. 0.100 mm
0.0039 in.
Rear 12.4±12.6 mm
0.488 -0.496 in. 11.25 mm
0.443 in. 0.013 mm
0.0005 in. 0.14 mm
0.0055 in.
*
TIR Total Indicator Reading (Measured On Vehicle)
BRAKE ROTOR - EXPORT
NOTE: Use the following information on all 4 wheel
disc brake vehicles that are equipped with BR3
sales code. When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.
LIMITS/SPECIFICATIONS
Brake Rotor Rotor Thickness Minimum Rotor
Thickness Rotor Thickness
Variation Rotor Runout*
Front 27.9-28.1 mm
1.098 -1.106 in. 26.5 mm
1.043 in 0.010 mm
0.0004 in. 0.080 mm
0.0031 in.
Rear 12.4-12.6 mm
0.488-0.496 in. 11.25 mm
0.443 in. 0.013 mm
0.0005 in. 0.14 mm
0.0055 in.
* TIR Total Indicator Reading (Measured On Vehicle)
SUPPORT PLATE - DRUM
BRAKE
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.
(Refer t o 5 - BRAKES/HYDRAULIC/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. (9) Disconnect the park brake cable from the park
brake actuation lever. (10) Using a suitable tool such as a 14 mm box
wrench (Fig. 92) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate. (11) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL) (12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle. (2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 93).
5s - 58 BRAKESRS
ROTOR (Continued)

(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)

If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate. (2) 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. (3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque. (4) Install the rear brake shoes on the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION). (5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.). (7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS) (8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE). (10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 94). It is a automatic-adjust-
ing type lever. The vehicle has four flexible steel parking brake
cables. They are: ² Front
² Intermediate
² Left rear
² Right rear
The front parking brake cable extends from the
parking brake lever. A steel equalizer bracket con-
nects the front parking brake cable to the left rear
and intermediate cable. The intermediate cable is
connected to the right rear cable using a parking
brake cable connector. On vehicles equipped with rear drum brakes, the
rear service brakes also act as the vehicle's parking
brakes. Vehicles equipped with rear disc brakes use a
small duo-servo brake assembly mounted to the each
rear disc brake caliper adapter as the parking brake.
The inside of the brake rotor (hat section of drum-in-
hat style brake rotor) is used as the parking brake
drum.
DESCRIPTION - EXPORT
The parking brake system on this vehicle features
a hand-operated parking brake lever. The lever is
located between the two front seats and requires a
special front cable.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment. When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel. The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park-
ing brake cables. An equalizer bracket is used at the rear end of the
front parking brake cable to distribute tension
equally to each parking brake cable.
Fig. 94 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5s - 60 BRAKESRS
WHEEL CYLINDERS (Continued)

izer, do not remove the locking pliers until
reinstallation of the cable is complete.(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 100).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 100). (5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 101). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 101).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
REMOVAL - PARKING BRAKE CABLE (RIGHT
REAR)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable. (4) Create slack in the rear parking brake cables
by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 102).
(5) Disconnect the right rear parking brake cable
from the connector on the intermediate cable (Fig.
103). (6) To remove the right parking brake cable hous-
ing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers (Fig. 104). The alternate method
using an aircraft type hose clamp will not work on
the right side of the vehicle. (7) Remove the brake shoes from the brake sup-
port plate. (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
Fig. 100 Parking Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 101 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
Fig. 102 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RS BRAKES5s-63
CABLES - PARKING BRAKE (Continued)