2004 CHRYSLER VOYAGER wipers

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
5sBrakes
6Clutch
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8EsElectronic Control Modules
8FEngine Systems
8FsEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8NsPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9sEngine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission/Transaxle
21sTransmission/Transaxle
22Tires/Wheels
22sTires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

If the vacuum supply is 12 inches Hg (40.5 kPa) or
more, the power brake booster is defective and must
be replaced. If the vacuum supply is below 12 inches
Hg, continue on with this BASIC TEST.
(6) Shut off the engine.
(7) Connect the vacuum gauge to the vacuum ref-
erence port on the engine intake manifold.
(8) Start the engine and observe the vacuum
gauge.
If the vacuum is still low, check the engine tune
and repair as necessary. If the vacuum is above 12
inches Hg, the hose or check valve to the booster has
a restriction or leak.
Once an adequate vacuum supply is obtained,
repeat the BASIC TEST.
VACUUM LEAK TEST
(1) Disconnect the vacuum hose on the vacuum
check valve, then place a vacuum gauge in line
between the vacuum hose and the valve.
(2) Start the engine.
(3) Allow the engine to warm up to normal operat-
ing temperature and engine idle.
(4) Using vacuum line pliers, close off the vacuum
supply hose near the booster, but before the vacuum
gauge, then observe the vacuum gauge.
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa)
in one minute, repeat the above steps to confirm the
reading. The vacuum loss should be less than 1.0
inch Hg in one minute time span. If the loss is more
than 1.0 inch Hg, replace the power brake booster. If
it is not, continue on with this test.
(5) Remove the pliers from the hose temporarily.
(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.
Do not move the pedal once the pressure is applied
or the test results may vary.
(7) Have an assistant reattach the vacuum line
pliers to the vacuum supply hose.
(8) Allow 5 seconds for stabilization, then observe
the vacuum gauge.
If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective.
(9) Remove the pliers and vacuum gauge.
REMOVAL
REMOVAL - LHD
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary toprevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove negative battery cable terminal from
battery.
(3) Remove positive battery cable terminal from
battery.
(4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
(6) Remove screw securing engine coolant filler
tube to battery tray.
(7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray.
(8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(9) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
the speed control servo.
(b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 58).
Fig. 58 Master Cylinder And Booster
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
5 - 42 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)

INSTALLATION
INSTALLATION - LHD
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 62).
It may be necessary to push in on booster input rod
as it is guided through the dash panel.
(2) Install the four nuts mounting the booster to
the dash panel (Fig. 61). Tighten the mounting nuts
to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 68).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(6) Install the silencer panel below the steering
column.(7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 69).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 59). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
(12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 58).
(13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 59).
Tighten the tube nuts to 17 N´m (145 in lbs.).
(14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
Fig. 67 RHD Booster Removal/Installation
1 - POWER BRAKE BOOSTER
2 - MASTER CYLINDER
Fig. 68 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
5 - 46 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)

(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.
Do not move the pedal once the pressure is applied
or the test results may vary. (7) Have an assistant reattach the vacuum line
pliers to the vacuum supply hose. (8) Allow 5 seconds for stabilization, then observe
the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective. (9) Remove the pliers and vacuum gauge.
REMOVAL
REMOVAL - LHD
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes). (2) Remove negative battery cable terminal from
battery. (3) Remove positive battery cable terminal from
battery. (4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray. (6) Remove screw securing engine coolant filler
tube to battery tray. (7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray. (8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray. (9) If vehicle is equipped with speed control:(a) Disconnect wiring harness connector from
the speed control servo. (b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL) (11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 66).
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(12) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as Mopar tBrake Parts Cleaner or equivalent.
(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 67). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to
power brake booster (Fig. 67). (15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
Fig. 66 Master Cylinder And Booster
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
RS BRAKES5s-45
POWER BRAKE BOOSTER (Continued)

INSTALLATION
INSTALLATION - LHD
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 70).
It may be necessary to push in on booster input rod
as it is guided through the dash panel. (2) Install the four nuts mounting the booster to
the dash panel (Fig. 69). Tighten the mounting nuts
to a torque of 29 N´m (250 in. lbs.). (3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 76).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION) (6) Install the silencer panel below the steering
column. (7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange. (9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 77).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston. (11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 67). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.). (12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 66). (13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 67).
Tighten the tube nuts to 17 N´m (145 in lbs.). (14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION) (15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
Fig. 76 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
Fig. 77 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
RS BRAKES5s-49
POWER BRAKE BOOSTER (Continued)

(2) Install clutch release bearing to lever. Apply
grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).
(3) Apply grease to pivot ball, and on release lever
at slave cylinder contact point.
(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 12).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 13).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
Fig. 10 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 11 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 12 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
6 - 8 CLUTCHRS
CLUTCH RELEASE LEVER AND BEARING (Continued)

INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove clutch master cylinder pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)

(10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45É and removing from
dash panel (Fig. 18).(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45É counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible ªclickº should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N´m (100 in. lbs.)
(Fig. 18).
(5) Install windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10 CLUTCHRS
MASTER CYLINDER - LHD (Continued)