2004 CHRYSLER VOYAGER wheel torque

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.
129).
(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. 130).
(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 131).(8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes.
(9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Fig. 128). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
Fig. 129 Measuring Park Brake Drum Diameter
Fig. 130 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 131 Setting Gauge To Park Brake Shoe
Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
5 - 74 BRAKES - BASERS
SHOES - PARKING BRAKE (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................75
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................75
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............75
DESCRIPTION - TRACTION CONTROL
SYSTEM............................76
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 76
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............77
OPERATION - TRACTION CONTROL
SYSTEM............................77
CAUTION
CAUTIONS..........................78
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................78
SPECIFICATIONS
ABS FASTENER TORQUE...............79
TONE WHEEL RUNOUT................79
WHEEL SPEED SENSOR AIR GAP........79
FRONT WHEEL SPEED SENSOR
REMOVAL.............................79
INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................80INSTALLATION.........................80
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................81
INSTALLATION.........................81
TONE WHEEL
INSPECTION - TONE WHEEL..............82
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................82
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................83
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................89
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION.........................89
OPERATION...........................90
REMOVAL
REMOVAL - LHD......................90
REMOVAL - RHD......................91
DISASSEMBLY - ICU....................93
ASSEMBLY - ICU.......................94
INSTALLATION
INSTALLATION - LHD..................94
INSTALLATION - RHD..................95
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE SYSTEM
This section covers the physical and operational
descriptions and the on-car service procedures for the
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control.
The purpose of the antilock brake system (ABS) is
to prevent wheel lockup under braking conditions on
virtually any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
DESCRIPTION - ANTILOCK BRAKE SYSTEM
(EXPORT)
Four-wheel disc antilock brakes are standard on all
models. The Mark 20e antilock brake system is used
on all models. Depending on whether the vehicle is a
left-hand drive (LHD) or right-hand drive (RHD)
model, the integrated control unit (ICU) is located in
one of two locations. On LHD models, the ICU is
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
RSBRAKES - ABS5-75

BLEEDING
When bleeding the ABS system, the following
bleeding sequence must be followed to insure com-
plete and adequate bleeding.
(1) Make sure all hydraulic fluid lines are installed
and properly torqued.
(2) Connect the DRBIIItscan tool to the diagnos-
tics connector. The diagnostic connector is located
under the lower steering column cover to the left of
the steering column.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does, clear
them using the DRB.
WARNING:
WHEN BLEEDING THE BRAKE SYSTEM
WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS
AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE
FLOW OF BRAKE FLUID AWAY FROM YOURSELF
AND THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME OUT
OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure. (Refer
to 5 - BRAKES - BASE - STANDARD PROCEDURE)
(5) Using the DRB, select ANTILOCK BRAKES,
followed by MISCELLANEOUS, then BLEED
BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, discon-
nect the scan tool and proceed.
(6) Bleed the base brake system a second time.
Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the hydrau-
lic system.
(7) Fill the master cylinder reservoir to the full
level.
(8) Test drive the vehicle to be sure the brakes are
operating correctly and that the brake pedal does not
feel spongy.
SPECIFICATIONS
ABS FASTENER TORQUE
(Refer to 5 - BRAKES - BASE - SPECIFICA-
TIONS)
TONE WHEEL RUNOUT
DESCRIPTION SPECIFICATION
Front Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
Rear Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
WHEEL SPEED SENSOR AIR GAP
DESCRIPTION SPECIFICATION
Front Sensor0.35 ± 1.20 mm
0.014 ± 0.047 in.
Rear Sensor0.40 ± 1.20 mm
0.016 ± 0.047 in.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly.
(3) Remove the sensor cable routing clamp screws.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Remove speed sensor cable grommets from
intermediate bracket on strut.
(5) Disconnect speed sensor cable from vehicle wir-
ing harness behind fender well shield.
(6) Remove the wheel speed sensor head mounting
bolt (Fig. 1).
(7) Remove sensor head from steering knuckle. If
sensor has seized due to corrosion,DO NOT USE
PLIERS ON SENSOR HEAD.Use a hammer and a
Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - DRIVESHAFT
4 - TONE WHEEL
5 - STEERING KNUCKLE
RSBRAKES - ABS5-79
BRAKES - ABS (Continued)

punch and tap edge of sensor ear, rocking the sensor
side-to-side until free.
(8) Remove front wheel speed sensor from vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts and
over extension of cables, resulting in an open cir-
cuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector. Be sure speed
sensor cable connector is fully seated and locked into
vehicle wiring harness connector.
(2) Install the bolts attaching the routing clamps
to the body of the vehicle. Tighten the bolts to a
torque of 14 N´m (125 in. lbs.).
(3) Insert speed sensor cable grommets into inter-
mediate bracket on strut.
(4) Install the wheel speed sensor head mounting
bolt (Fig. 1). Tighten the bolt to a torque of 13 N´m
(115 in. lbs.)
(5) Install the wheel and tire assembly on vehicle.
(6) Lower vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
REAR WHEEL SPEED SENSOR
-AWD
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness.
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips along brake hose and tubing.(4) Remove bolt securing wheel speed sensor cable
metal clip to rear of axle. Remove metal clip from
cable if necessary.
CAUTION: If speed sensor head has seized due to
corrosion, do not use pliers on speed sensor head
in an attempt to remove it. Use a hammer and a
punch and tap mounting flange edge side-to-side,
rocking the sensor until free.
(5) Remove wheel speed sensor head attaching
bolt.
(6) Remove wheel speed sensor head from the axle,
and remove sensor from vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as indicated may
result in contact with moving parts or over-exten-
sion of cables, resulting in an open circuit.
(1) Install wheel speed sensor head in axle flange.
CAUTION: Prior to installing the speed sensor head
attaching bolt, the plastic anti-rotation pin must be
fully seated into the bearing flange.
(2) Install wheel speed sensor head attaching bolt.
Tighten bolt to a torque 10 N´m (90 in. lbs.).
(3) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone
wheel. (Refer to 5 - BRAKES - SPECIFICATIONS)
CAUTION: When installing wheel speed sensor
cable in the routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake hose if damaged.
(4) Install speed sensor cable under leaf spring
onto brake hose and tubing utilizing routing clips to
secure it in place.
(5) Install metal routing clip on speed sensor cable
and mount it to rear of axle with mounting bolt.
Tighten mounting bolt to 16 N´m (140 in. lbs.).
(6) Connect wheel speed sensor cable to vehicle
wiring harness.Be sure speed sensor cable con-
nector is fully seated and locked into vehicle
wiring harness connector.
(7) Install speed sensor cable grommet into the
floor pan, being sure the grommet is fully seated into
the access hole.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
5 - 80 BRAKES - ABSRS
FRONT WHEEL SPEED SENSOR (Continued)

ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact eachother or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 94 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

DISC BRAKE CALIPER ADAPTERREMOVAL - FRONT DISC BRAKE CALIPERADAPTER ...........................30
INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER ....................30
DISC BRAKE CALIPER GUIDE PINS REMOVAL - DISC BRAKE CALIPER GUIDEPINS (TRW BRAKES) ..................30
INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) .............30
DRUM REMOVAL .............................31
INSTALLATION .........................31
FLUID DIAGNOSIS AND TESTING - BRAKE FLUIDCONTAMINATION .....................31
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING .....................31
SPECIFICATIONS BRAKE FLUID ........................32
JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK . 32
OPERATION - NON-ABS JUNCTION BLOCK . . 32
REMOVAL - NON-ABS JUNCTION BLOCK ....32
INSTALLATION - NON-ABS JUNCTION BLOCK . 32
MASTER CYLINDER DESCRIPTION DESCRIPTION ........................33
DESCRIPTION - RHD ..................34
OPERATION ...........................34
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING ..................34
REMOVAL REMOVAL - LHD ......................35
REMOVAL - RHD ......................36
DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................36
ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) .........................37
INSTALLATION INSTALLATION - LHD ..................37
INSTALLATION - RHD ..................38
PEDALS - ADJUSTABLE REMOVAL .............................38
INSTALLATION .........................40
PEDAL TORQUE SHAFT - RHD REMOVAL .............................42
INSTALLATION .........................43
POWER BRAKE BOOSTER DESCRIPTION .........................43
OPERATION ...........................44
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER ...........................44
REMOVAL REMOVAL - LHD ......................45
REMOVAL - RHD ......................47 INSTALLATION
INSTALLATION - LHD ..................49
INSTALLATION - RHD ..................50
PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE(HEIGHT SENSING) ....................51
OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................51
DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT
SENSING) ...........................52
REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) ....................53
ROTOR DIAGNOSIS AND TESTING - BRAKE ROTOR . . 54
STANDARD PROCEDURE - BRAKE ROTORMACHINING ..........................56
REMOVAL - FRONT BRAKE ROTOR ........57
INSTALLATION - FRONT BRAKE ROTOR .....57
SPECIFICATIONS BRAKE ROTOR .......................57
BRAKE ROTOR - EXPORT ..............58
SUPPORT PLATE - DRUM BRAKE REMOVAL .............................58
INSTALLATION .........................58
WHEEL CYLINDERS REMOVAL .............................59
INSPECTION ..........................59
INSTALLATION .........................60
PARKING BRAKE DESCRIPTION DESCRIPTION ........................60
DESCRIPTION - EXPORT ...............60
OPERATION ...........................60
STANDARD PROCEDURE STANDARD PROCEDURE - PARKINGBRAKE AUTOMATIC ADJUSTER TENSION
RELEASE ...........................61
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION
RESET .............................61
CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE(FRONT) ............................62
REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) ......................62
REMOVAL - PARKING BRAKE CABLE (RIGHT REAR) ........................63
REMOVAL - PARKING BRAKE CABLE (LEFT REAR )..............................64
INSTALLATION INSTALLATION - PARKING BRAKE CABLE(FRONT) ............................65
5s - 2 BRAKESRS

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)

(12) Install the wheel and tire assemblies. 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.). (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
(TRW 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.
13). (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. 14).
(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. 15).
Fig. 14 Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
Fig. 15 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
5s - 16 BRAKESRS
BRAKE PADS/SHOES - FRONT (Continued)