2004 CHRYSLER VOYAGER brake rotor

If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing the
rotor from the hub, place a chalk mark across both
the rotor and the one wheel stud closest to where the
high runout measurement was taken. This way, the
original mounting spot of the rotor on the hub is
indexed (Fig. 85). Remove the rotor from the hub. NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an
accurate indicator reading.
Mount Dial Indicator, Special Tool C-3339, and
Mounting Adaptor, Special Tool SP-1910, to the steer-
ing knuckle. Position the indicator stem so it contacts
the hub face near the outer diameter. Care must be
taken to position stem outside of the stud circle, but
inside of the chamfer on the hub rim (Fig. 86). Hub runout should not exceed 0.03 mm (0.0012
inch). If runout exceeds this specification, the hub
must be replaced. (Refer t o 2 - SUSPENSION/
FRONT/HUB / BEARING - REMOVAL)(Refer to 2 -
SUSPENSION/REAR/HUB / BEARING - REMOVAL) If the hub runout does not exceed this specifica-
tion, install the rotor back on the hub, aligning the
chalk marks on the rotor with a wheel mounting
stud, two studs apart from the original stud (Fig. 87).
Tighten nuts in the proper sequence and torque to
specifications. Recheck brake rotor runout to see if the runout is
now within specifications. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTOR - SPECIFICA-
TIONS) If runout is not within specifications, reface or
replace the brake rotor. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE)
Fig. 83 Checking Rotor For Thickness
1 - CALIPER
Fig. 84 Checking Rotor Runout
1 - SPECIAL TOOL SP-1910
2 - 10 MILLIMETERS FROM EDGE
3 - DISC SURFACE
4 - SPECIAL TOOL C-3339
Fig. 85 Marking Rotor and Wheel Stud
1 - CHALK MARK
RS BRAKES5s-55
ROTOR (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)

Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination. When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required. Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut. 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. Specifi-
cations for brake rotor machining can be found in
this section's specification table. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
SPECIFICATIONS)
REMOVAL - FRONT BRAKE ROTOR
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance. (2) Remove the front wheel and tire assembly.
(3) Remove the two mounting bolts securing the
disc brake caliper adapter with brake caliper to the
steering knuckle (Fig. 91). (4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 91).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this. (5) Remove any retainer clips from the wheel
mounting studs. (6) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 91).
INSTALLATION - FRONT BRAKE ROTOR
(1) Install the brake rotor back on the hub and
bearing (Fig. 91). (2) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 91). (3) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque. (4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.). (5) Lower vehicle to the ground.
SPECIFICATIONS
BRAKE ROTOR
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.
Fig. 90 Rear Brake Rotor Minimum Thickness Markings
1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM
DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE
2 - REAR ROTOR
Fig. 91 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RS BRAKES5s-57
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)

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)

(6) Remove the front parking brake cable housing
from body outrigger bracket. Cable is removable by
sliding a 14 mm box wrench over the cable retainer
and compressing the three retaining fingers. Alter-
nate method: Use an aircraft type hose clamp and
screwdriver. (7) Remove the four mounting nuts from the bot-
tom of the parking brake lever bracket. (8) Lower vehicle.
(9) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL) (10) If equipped with a manual transaxle, remove
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- REMOVAL) (11) Unhook the end of the parking brake cable
from the lever mechanism. (12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers. (13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment. (14) Lift the parking brake lever and slide the
parking brake cable out. (15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle. (2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket. (3) Hook the end of the parking brake cable on the
parking brake lever mechanism. (4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan. (5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION) (6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION) (7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place. (9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place. (10) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 113). (12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables. (13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake. The park-
ing brake is set to keep the hub/bearing and
axle shaft from rotating when loosening the
hub nut. (2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE). (3) Remove the wheel and tire assembly.
(4) AWD only - Remove the cotter pin and nut
retainer (Fig. 114) from the stub shaft of the outer
C/V joint.
Fig. 114 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RS BRAKES5s-69
LEVER - PARKING BRAKE (EXPORT) (Continued)

(5) AWD only - Remove the spring washer (Fig.
115) from the stub shaft of the outer C/V joint.
(6) AWD only - Remove the hub nut and washer
(Fig. 116) from the stub shaft of the outer C/V joint.
(7) Release the parking brake. (8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 117).
(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 118).
Fig. 115 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 116 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 117 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 118 Removing Caliper Guide Pin Bolts
1 - DISC BRAKE CALIPER
2 - ADAPTER
3 - AXLE
4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
5s - 70 BRAKESRS
SHOES - PARKING BRAKE (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)