2004 DODGE TOWN AND COUNTRY steering

(3) Install two upper mounting bolts attaching
pedals assembly to steering column support bracket
on dash panel. Do not fully tighten at this time.
(4) Install four nuts attaching pedals assembly and
power brake booster to dash panel (Fig. 61). (5) Tighten four booster mounting nuts and two
upper mounting bolts to 28 N´m (21 ft. lbs.) torque. (6) Route pedal adjuster cable up and over right
side of pedals assembly and steering column bracket, then down through hole in steering column bracket
as shown (Fig. 60). Attach end of cable to gear box.
(7) Place adjuster cable through loop on right side
of steering column bracket as shown (Fig. 60). (8) Install booster input rod onto brake pedal pin
and install a NEW retaining clip. (9) Connect wiring connector connecting vehicle
wiring harness to pedal wiring harness (Fig. 58). (10) Connect routing clips retaining vehicle wiring
harness to pedal wiring harness (Fig. 58). (11) Install brake lamp switch bracket on pedals
assembly. Tighten mounting nuts to 6 N´m (50 in.
lbs.) torque. (12) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
57). (13) Install steering column onto lower mounting
studs with nuts started, then install column onto
upper mounting studs and install two upper mount-
ing nuts. Tighten upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque. (14) Install column shaft coupling onto intermedi-
ate shaft and install pinch bolt. Make sure rounded
side of intermediate shaft is matched to the curva-
ture of the coupling. Tighten pinch bolt to 28 N´m
(250 in. lbs.) torque. (15) Remove retainer holding steering wheel in
place on steering column. (16) Attach shift cable to bracket on column.
(17) Connect shift cable end to shift lever mecha-
nism pin (Fig. 55). (18) If equipped, connect PRNDL cable to end of
shift lever mechanism pin and column bracket (Fig.
55). (19) Connect column wiring harness connectors (as
equipped) to SKIM, BTSI solenoid, ignition switch,
multi-function switch, and clockspring. (20) Install lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - INSTALLATION)
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.
(21) Install and adjust NEW brake lamp switch.
(Refer t o 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION) (22) Install instrument panel lower left reinforce-
ment (Fig. 54). (23) Attach hood release to lower left reinforce-
ment.
Fig. 60 Drive Cable Routing
1 - ADJUSTER CABLE
2 - ROUTING LOOP
3 - CABLE ATTACHMENT AT MOTOR
4 - GEAR DRIVE
5 - CABLE ATTACHMENT AT GEAR BOX
6 - STEERING COLUMN BRACKET
Fig. 61 Booster Mounting (Typical)
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
RS BRAKES5s-41
PEDALS - ADJUSTABLE (Continued)

(24) Install knee blocker reinforcement plate (Fig.
53). (25) Connect parking brake release link to release
handle. (26) Install data link diagnostic connector to
mounting hole in reinforcement plate. (27) Install lower steering column cover/knee
blocker (Fig. 53). (28) Install throttle cable onto throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery following special Diagnosis And Testing pro-
cedure. (Refer t o 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING) (30) Test operation of adjustable pedals and all
functions that are steering column operated. If appli-
cable, reset radio and clock. (31) Road test the vehicle to ensure proper opera-
tion of steering and brake systems.
PEDAL TORQUE SHAFT - RHD
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL) (2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL) (3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Remove
the link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled. (4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 62). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled. (5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig.
63). (6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 63). (7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
Fig. 62 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
Fig. 63 BOOSTER, TORQUE SHAFT AND PEDAL MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT
5s - 42 BRAKESRS
PEDALS - ADJUSTABLE (Continued)

(16) Disconnect vacuum hose from check valve
located on vacuum booster. DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER. (17) Inside vehicle, remove silencer panel under
instrument panel below steering column. (18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 68). (19) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin. Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling. (20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 69).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 70).
CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.
Fig. 67 Master Cylinder Mounting
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 68 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
Fig. 69 Booster Mounting
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 70 Booster Removal/Installation
5s - 46 BRAKESRS
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)

(6) Road test the vehicle to verify proper operation
of the brake system.
ROTOR
DIAGNOSIS AND TESTING - BRAKE ROTOR
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action. Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock-back. This increases
guide pin sleeve wear due to the tendency of the cal-
iper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the
machined disc braking surface should be checked and
inspected.
BRAKING SURFACE INSPECTION
Light braking surface scoring and wear is accept-
able. If heavy scoring or warping is evident, the rotor
must be refaced or replaced. (Refer t o 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTORS - STAN-
DARD PROCEDURE). Excessive wear and scoring of the rotor can cause
improper lining contact on the rotor's braking sur-
face. If the ridges on the rotor are not removed before
new brake shoes are installed, improper wear of the
shoes will result. If a vehicle has not been driven for a period of
time, the rotor's braking surface will rust in the
areas not covered by the brake shoes at that time.
Once the vehicle is driven, noise and chatter from
the disc brakes can result when the brakes are
applied. Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced. If cracks or burned spots are evi-
dent, the rotor must be replaced.
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if it is worn
below minimum thickness or if machining the rotor
will cause its thickness to fall below specifications.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Minimum thickness specifications are cast on the
rotor's unmachined surface (Fig. 82). Limits can also
be found in this section's specification table. (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
SPECIFICATIONS)
ROTOR THICKNESS VARIATION
Thickness variation in a rotor's braking surface
can result in pedal pulsation, chatter and surge. This
can also be caused by excessive runout in the rotor or
the hub. Rotor thickness variation measurements should be
made in conjunction with measuring runout. Mea-
sure thickness of the brake rotor at 12 equal points
around the rotor braking surface with a micrometer
at a radius approximately 25 mm (1 inch) from edge
of rotor (Fig. 83). If thickness measurements vary
beyond the specification listed in the specifaction
table (Refer t o 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTOR - SPECIFICATIONS), the rotor should
be refaced or replaced. (Refer t o 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE).
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP-
1910 on steering arm. The dial indicator plunger
should contact braking surface of rotor approximately
ten millimeters from edge of rotor (Fig. 84). Check
lateral runout on both sides of the rotor, marking the
low and high spots on both. Runout limits can be
found in the specification table in this section. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/RO-
TOR - SPECIFICATIONS)
Fig. 82 Minimum Brake Rotor Thickness Markings (Typical)
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
5s - 54 BRAKESRS
PROPORTIONING VALVE (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)

CABLES - PARKING BRAKE
(EXPORT)
REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE
(Refer t o 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer t o 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE). (2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal. (3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel. (6) Remove the steering column cover from the
lower instrument panel. (7) Remove the reinforcement from the lower
instrument panel. (8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 110).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable. (10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
NOTE: When removing the lower mounting bolt,
push the park brake pedal down 5 clicks to access
the lower mounting bolt.
(11) Remove the lower bolt mounting the park
brake pedal to the body (Fig. 111). (12) Remove the forward nut mounting the park
brake pedal to the body (Fig. 111). (13) Remove the upper bolt mounting the park
brake pedal to the body (Fig. 111).
(14) Pull downward on front park brake cable
while rotating park brake pedal mechanism out from
behind junction block. (15) Remove park brake pedal release link from
park brake mechanism. (16) Remove the warning lamp ground switch con-
nector from the park brake pedal mechanism (Fig.
111). (17) Remove front park brake cable button from
park brake pedal mechanism. Tap end housing for
front park brake cable out of park brake pedal mech-
anism.
INSTALLATION
(1) Install park brake cable end housing into park
brake pedal mechanism. (2) Install cable retainer onto the park brake cable
strand and then install retainer into pedal bracket. (3) Install cable strand button into the clevis on
the park brake pedal mechanism. (4) Install wiring harness connector on warning
indicator lamp ground switch.Fig. 110 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 111 PARKING BRAKE LEVER MOUNTING
1 - WIRE HARNESS CONNECTOR
2 - LEVER MECHANISM
3 - FRONT CABLE
RS BRAKES5s-67

(5) Install the park brake release rod on the
release mechanism of the park brake pedal. (6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle. (7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 111). (8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 111). (9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 111). (10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.). (11) Verify that the park brake pedal is in the fully
released (full up) position. (12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 110).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer t o 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism. (16) Install the electrical junction block on the
instrument panel. (17) Install the reinforcement on the lower instru-
ment panel. (18) Install the steering column lower cover on the
lower instrument panel. (19) Install the silencer panel under the instru-
ment panel. (20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door. (22) Install the negative (ground) cable on the bat-
tery. (23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (2) 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 (Fig. 112).
(3) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 113).
(4) Remove the equalizer from the front parking
brake cable. (5) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever mechanism to rotate around to
its stop and remove the tension from the adjuster
and front park brake cable.
Fig. 112 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 113 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5s - 68 BRAKESRS
LEVER - PARKING BRAKE (Continued)