2005 CHRYSLER VOYAGER ail

(2) Remove the bolts securing the stabilizer bar to
links on each end of the bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bush-
ing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
(5) If the links need to be serviced, remove the
upper link arm to bracket bolt. Then remove link
arm from frame rail attaching bracket.
REMOVAL - FWD
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove the bolts securing the stabilizer bar to
links on each side of bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bush-
ing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
REMOVAL - FWD - FOLD-IN-FLOOR SEATING
(1) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(2) At each end of the stabilizer bar, remove the
nuts and bolts securing the bar to the links (Fig. 41).
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bush-
ing retainers to the rear axle (Fig. 41).
(4) Remove the stabilizer bar from the vehicle.
INSTALLATION
INSTALLATION - AWD
(1) Install the stabilizer bar on the rear axle.
(2) Install bushing retainer bolts. Do not tighten at
this time.
(3) Install bolts connecting links to stabilizer bar.
Do not tighten at this time.
(4) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link bolts Ð 61 N´m (45 ft. lbs.)
INSTALLATION - FWD
(1) Lift the stabilizer bar onto the rear axle and
install the two retainer mounting bolts. DO NOT
TIGHTEN.
(2) Install the bolts attaching the stabilizer bar
links to the stabilizer bar. DO NOT TIGHTEN.
(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link Ð 61 N´m (45 ft. lbs.)
INSTALLATION - FWD - FOLD-IN-FLOOR
SEATING
(1) Lift the stabilizer bar onto the rear axle, hook-
ing the bottom of the bushing retainers on the axle,
then install the two retainer mounting bolts (Fig. 41).
DO NOT TIGHTEN AT THIS TIME.
(2) Install the bolts and nuts attaching the stabi-
lizer bar links to the stabilizer bar (Fig. 41). DO NOT
TIGHTEN AT THIS TIME.
(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link Ð 61 N´m (45 ft. lbs.)
TRACK BAR
DESCRIPTION
On front-wheel-drive applications of this vehicle
that are equipped with single leaf rear springs, a
track bar is used on the rear axle (Fig. 1).
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
Fig. 41 Stabilizer Bar With Fold-In-Floor Seating
1 - LINK NUT
2 - LINK BOLT AND NUT
3 - STABILIZER LINK
4 - STABILIZER BAR
5 - REAR AXLE
6 - BOLTS
RSREAR SUSPENSION2-45
STABILIZER BAR (Continued)

CROSS CAMBER
Cross camber is the difference between left and
right camber. To achieve the cross camber reading,
subtract the right side camber reading from the left.
For example, if the left camber is +0.3É and the right
camber is 0.0É, the cross camber would be +0.3É.
CASTER
Caster is the forward or rearward tilt of the steer-
ing knuckle in reference to the position of the upper
and lower ball joints. Caster is measured in degrees
of angle relative to a true vertical center line. This
line is viewed from the side of the tire and wheel
assembly (Fig. 2).
²Forward tilt (upper ball joint ahead of lower)
results in a negative caster angle.
²Rearward tilt (upper ball joint trailing lower)
results in a positive caster angle.
Although caster does not affect tire wear, a caster
imbalance between the two front wheels may cause
the vehicle to lead to the side with the least positive
caster.
CROSS CASTER
Cross caster is the difference between left and
right caster.
TOE
Toe is the inward or outward angle of the wheels
as viewed from above the vehicle (Fig. 3).
²Toe-in is produced when the front edges of the
wheels on the same axle are closer together than the
rear edges.
²Toe-out is produced when the front edges of the
wheels on the same axle are farther apart than the
rear edges.
Toe-in and toe-out can occur at the front wheels
and the rear wheels.
Toe is measured in degrees or inches. The mea-
surement identifies the amount that the front of the
wheels point inward (toe-in) or outward (toe-out). Toe
is measured at the spindle height. Zero toe means
the front and rear edges of the wheels on the same
axle are equally distant.
Fig. 2 CasterFig. 3 Toe
1 - TOE-IN
2 - TOE-OUT
2 - 48 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

THRUST ANGLE
Thrust angle is the averaged direction the rear
wheels are pointing in relation to the vehicle's center
line (Fig. 6). The presence of negative or positive
thrust angle causes the rear tires to track improperly
to the left or right of the front tires (dog tracking).
²Negative thrust angle means the rear tires are
tracking to the left of the front tires.
²Positive thrust angle means the rear tires are
tracking to the right of the front tires.
Improper tracking can cause undue tire wear, a
lead or pull and a crooked steering wheel. Excessive
thrust angle can usually be corrected by adjusting
the rear wheel toe so that each wheel has one-half of
the total toe measurement.
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or
Grinding On Turns1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting frame
rail and reposition engine as required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
6. Worn tires 6. Replace tires
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Fig. 6 Thrust Angle
2 - 50 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

NOTE: Prior to reading the vehicle's alignment
readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by
grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The
bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Read the vehicle's current front and rear align-
ment settings. Compare the vehicle's current align-
ment settings to the vehicle specifications for camber,
caster and toe-in. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - SPECIFICATIONS)
(4) If front camber and caster are not within spec-
ifications, proceed to CAMBER AND CASTER below.
If caster and camber are within specifications, pro-
ceed to TOE which can be found following CAMBER
AND CASTER. Rear camber, caster and toe are not
adjustable. If found not to be within specifications,
reinspect for damaged suspension or body compo-
nents and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are
determined at the time the vehicle is designed, by
the location of the vehicle's suspension components.
This is referred to as NET BUILD. The result is no
required adjustment of camber and caster after the
vehicle is built or when servicing the suspension
components. Thus, when performing a wheel align-
ment, caster and camber are not normally considered
adjustable angles. Camber and caster should be
checked to ensure they meet vehicle specifications.
If front camber is found not to meet alignment
specifications, it can be adjusted using an available
camber adjustment bolt package. Before installing a
camber adjustment bolt package on a vehicle found
to be outside the specifications, inspect the suspen-
sion components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles
wheel alignment by heating, bending or by perform-
ing any other modification to the vehicle's front
suspension components or body.
If camber readings are not within specifications,
use the following procedure to install the front cam-
ber adjustment bolt package and then adjust front
camber.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2
flange bolts, 2 cam bolts, 2 dog bone washers, and 4
nuts. This package services both sides of the vehicle.
Use the package to attach the strut clevis bracket to
the steering knuckle after the strut clevis brackethas been modified. To install and adjust the camber
adjustment bolt package, follow the procedure below.
(1) Raise the vehicle until its tires are not support-
ing the weight of the vehicle.
(2) Remove the front tire and wheel assemblies.
CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
brake flex hose when removed from the strut
assembly. If necessary use a wire hanger to sup-
port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem-
bly.
CAUTION: The knuckle to strut assembly attaching
bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the
bolts stationary.
(3) Remove the top and bottom, strut clevis
bracket to steering knuckle attaching bolts (Fig.
7)and discard. Separate the steering knuckle from
the strut clevis bracket and position steering knuckle
so it is out of the way of the strut.
CAUTION: When slotting the bottom mounting hole
on the strut clevis bracket, do not enlarge the hole
beyond the indentations on the sides of the strut
clevis bracket (Fig. 8).
Fig. 7 Clevis Bracket To Steering Knuckle Attaching
Bolts
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
RSWHEEL ALIGNMENT2-53
WHEEL ALIGNMENT (Continued)

(9) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
(10) Position trilobal boot to interface with the tri-
pod housing. The lobes of the boot must be properly
aligned with the recess's of the tripod housing.
CAUTION: The following positioning procedure deter-
mines the correct air pressure inside the inner CV
joint assembly prior to clamping the sealing boot to
inner CV joint housing. If this procedure is not done
prior to clamping sealing boot to CV joint housing
sealing boot durability can be adversely affected.
CAUTION: When venting the inner CV joint assembly,
use care so that the inner CV sealing boot does not
get punctured, or in any other way damaged. If sealing
boot is punctured, or damaged in any way while being
vented, the sealing boot can not be used.
(11) Insert a trim stick between the CV joint hous-
ing and the sealing boot insert to vent inner CV joint
assembly (Fig. 22).When inserting trim stick
between tripod housing and sealing boot
ensure trim stick is held flat and firmly against
the tripod housing. If this is not done damage
to the sealing boot can occur.
(12)
With trim stick inserted between sealing boot
insert and the CV joint housing, position the intercon-
necting shaft so it is at the center of its travel in the
tripod joint housing. Remove the trim stick from
between the sealing boot insert and the CV joint hous-
ing.This procedure will equalize the air pressurein the CV joint, preventing premature sealing
boot failure.
(13) Clamp CV joint sealing boot to CV joint, using
required procedure for type of boot clamp application.
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
(1) Place crimping tool C-4975-A over bridge of
clamp (Fig. 23).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 24).
Fig. 22 Trim Stick Inserted for Venting CV Joint
1 - INNER CV JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER CV JOINT HOUSING
4 - TRIM STICK
Fig. 23 Crimping Tool Installed on Sealing Boot Clamp
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 24 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975-A
4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
RSHALF SHAFT - FRONT3-9
CV BOOT - INNER (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................63
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................64
STANDARD PROCEDURE - CABLE END
CLEANING AND LUBRICATION...........65
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE
CABLES............................65
CABLE - PARKING BRAKE FRONT
REMOVAL
REMOVAL...........................66
REMOVAL - FOLD-IN-FLOOR SEATING.....66
REMOVAL - EXPORT..................67
INSTALLATION
INSTALLATION.......................67
INSTALLATION - FOLD-IN-FLOOR SEATING . 68
INSTALLATION - EXPORT...............68
CABLE - PARKING BRAKE INTERMEDIATE
REMOVAL.............................69
INSTALLATION.........................69CABLE - PARKING BRAKE REAR
REMOVAL
REMOVAL - RIGHT REAR...............70
REMOVAL - LEFT REAR................71
REMOVAL - FOLD-IN-FLOOR SEATING.....72
INSTALLATION
INSTALLATION - RIGHT REAR...........74
INSTALLATION - LEFT REAR............75
INSTALLATION - FOLD-IN-FLOOR
SEATING............................75
LEVER - PARKING BRAKE
REMOVAL.............................75
INSTALLATION.........................76
LEVER - PARKING BRAKE (EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE.......................77
INSTALLATION - PARKING BRAKE LEVER
AND FRONT CABLE...................77
SHOES - PARKING BRAKE
REMOVAL.............................78
INSTALLATION.........................84
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 85
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components:
²Brake pedal
²Power brake booster
²Master cylinder
²Brake tubes and hoses
²Proportioning valve (non-ABS vehicles only)
²Disc brakes
²Drum brakes
²Brake lamp switch
²Brake fluid level switch
²Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options.
The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other.
For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly.
The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
come in contact with a hub mounted drum (drum for
disc/drum brakes or drum-in-hat for disc/disc brakes)
and hold it in place.
RSBRAKES - BASE5-3

WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoes and braking surfaces of brake rotor or drum,
and external surfaces of hub and bearing assembly.
CAUTION: Brake rotor and caliper handling must be
done in such a way as to avoid damage to the rotor,
especially the machined surfaces, and scratching or
nicking of the brake linings.
CAUTION: Only the recommended jacking or hoist-
ing procedures for this vehicle are to be used
whenever it is necessary to lift a vehicle. Failure to
raise a vehicle utilizing the recommended lift points
can result in damage to the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING - STAN-
DARD PROCEDURE)
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated.6. Refer to appropriate Diagnostic
information.
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)

DESCRIPTION - DISC BRAKES (REAR)
There are several distinctive features to the rear
disc brakes on this vehicle (Fig. 8). The single piston,
floating caliper rear disc brake system includes a hub
and bearing assembly, adapter, rotor, caliper, and
brake shoes.
This vehicle is equipped with a caliper having a 42
mm (1.65 in.) piston and uses a 15 inch solid non-
vented brake rotor. The brake rotor is described as a
drum-in-hat style because of its dual role as a brak-
ing disc and parking brake drum.
The parking brake system on vehicles equipped
with rear disc brakes consists of a small duo-servo
drum brake mounted to the caliper adapter and uses
the interior of the rear disc brake rotor as a drum
(hat section of drum-in-hat style brake rotor).
The outboard rear disc brake shoes (pads) are side-
oriented. The shoes are marked indicating which side
they belong on.
DESCRIPTION - DISC BRAKES (EXPORT)
All vehicles are equipped with Four-Wheel-Disc
brakes. Both 15º (BRE) and 16º (BR3) disc/disc brake
systems are available. The disc brakes are manufac-
tured by Continental Teves. The BR3 system is stan-
dard equipment on all-wheel drive and all right-hand
drive models. It is optional on other models.
The BR3 system features larger, externally vented
front brake rotors.
Although there are different disc/disc systems, they
are serviced using the same service procedures. Some
specifications differ.
DESCRIPTION - DRUM BRAKES (REAR)
This vehicle's rear wheel drum brakes are a two-
shoe, internal-expanding type with an automatic
adjuster screw. The automatic adjuster screw is
located directly below the wheel cylinder that is
mounted near the top of the brake assembly (Fig. 9).
These and two brake shoes (and attaching parts) are
mounted to a support plate at each rear wheel. A
brake drum covers each brake assembly.
OPERATION
OPERATION - DISC BRAKES (FRONT)
When the brakes are applied, fluid pressure is sent
to each brake caliper. The pressure at the caliper is
exerted equally against the caliper piston. The pres-
sure applied to the piston is transmitted directly to
the inboard brake shoe. This forces the shoe lining
against the inner surface of the brake rotor. At the
same time, fluid pressure within the caliper piston
bore forces the caliper to slide inward on its guide
pins. This action brings the outboard shoe lining into
contact with the outer surface of the brake rotor.
This pressure on both sides of the brake rotor causes
friction, bringing the vehicle to a stop.
When the brake pedal is released, so is the fluid
pressure. The piston seal inside the caliper is
designed to pull the piston back into the bore of the
caliper when the brake pedal is released (Fig. 10).
This action helps maintain the proper brake shoe-to-
rotor clearance.
Fig. 8 Rear Disc Brakes
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 9 Drum Brake Assembly (Right Shown)
1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
3 - AUTOMATIC ADJUSTER LEVER
4 - TENSION CLIP
5 - AUTOMATIC ADJUSTER ASSEMBLY
RSBRAKES - BASE5-13
HYDRAULIC/MECHANICAL (Continued)