Chrysler RG Voyager. Manual — part 663

(8) Lift floor mat for access to park brake cable

and floor pan. Pull the seal and the park brake cable
(Fig. 102) out of the floor pan of vehicle.

(9) Pull parking brake cable strand end forward

and disconnect button from clevis. Tap cable housing
end fitting out of pedal assembly bracket.

(10) Remove cable retainer from the parking brake

lever (pedal) assembly bracket.

(11) Pull front parking brake cable assembly out of

vehicle through hole in floor pan.

REMOVAL - FOLD-IN-FLOOR SEATING

(1) Release the parking brake.
(2) Raise

and

support

the

vehicle.

(Refer

to

LUBRICATION

&

MAINTENANCE/HOISTING

-

STANDARD PROCEDURE)

(3) Manually release the automatic self-adjusting

mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).

(4) Remove the front cable from the equalizer (Fig.

103).

(5) Remove the locking pliers from the cable that

were installed during Step 3.

(6) Remove the front cable from the routing clips

fastened to the underbody of the vehicle (Fig. 104).

Fig. 102 Front Park Brake Cable At Floor Pan

1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN

Fig. 103 Parking Brake Cable Equalizer

1 - INTERMEDIATE BRACKET
2 - EQUALIZER
3 - LEFT REAR CABLE
4 - RIGHT REAR CABLE
5 - FRONT CABLE

Fig. 104 Front Parking Brake Cable Routing

1 - SCREW
2 - ROUTING BRACKET
3 - SCREW
4 - INTERMEDIATE BRACKET
5 - FRONT CABLE
6 - ROUTING BRACKET

RS

BRAKES - BASE

5 - 65

CABLE - PARKING BRAKE FRONT (Continued)

(7) Place a 13 mm 12-point box wrench over the

cable retainer at the intermediate bracket as shown
to collapse the retainer fingers (Fig. 105).

(8) Pull the cable out of the intermediate bracket.
(9) Lower the vehicle.
(10) Remove the left front door sill molding.
(11) Remove the left front kick panel.
(12) Pull the parking brake cable strand forward

and disconnect the end button from the lever (pedal)
assembly mechanism reel (Fig. 106).

(13) Slide the cable out of the lever bracket.
(14) Lift back the carpet and pull the cable seal

loose from the floor pan (Fig. 102).

(15) Pull the front parking brake cable assembly

out of the vehicle through the hole in the floor pan.

REMOVAL - EXPORT

(Refer to 5 - BRAKES - BASE/PARKING BRAKE/

LEVER - REMOVAL)

INSTALLATION

INSTALLATION

(1) Pass

front

parking

brake

cable

assembly

through hole in floor pan from the inside of the vehi-
cle.

(2) Pass cable strand button through the hole in

the lever (pedal) assembly bracket.

(3) Install cable retainer onto the park brake cable

and then install cable retainer into pedal assembly
bracket.

(4) Install the end of the park brake cable into the

retainer previously installed into the park brake
pedal bracket.

(5) Install cable strand button into the clevis on

the park brake pedal mechanism.

(6) Install the front park brake cable floor pan seal

into hole in floor pan. Seal is to be installed so the
flange on the seal is flush with the floor pan (Fig.
102). Fold carpeting back down on floor.

(7) Raise vehicle.
(8) Insert brake cable and housing into body out-

rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 101).

(9) Manually reset the automatic self-adjusting

mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).

(10) Assemble the park brake cables onto the park

brake cable equalizer (Fig. 100).

(11) Lower vehicle and apply the park brake pedal

1 time. This will seat the parking brake cables.

INSTALLATION - FOLD-IN-FLOOR SEATING

(1) Pass most of the front parking brake cable

assembly down through hole in the floor pan from
inside the vehicle.

(2) Pass the lever-end cable strand button through

the hole in the lever (pedal) assembly bracket.

(3) Install the end of the cable housing into the

retainer installed into the park brake pedal bracket.

Fig. 105 Cable Removal Using Wrench

1 - CABLE RETAINER
2 - 12-POINT BOX WRENCH

Fig. 106 Parking Brake Lever Assembly

1 - WIRING CONNECTOR
2 - MECHANISM REEL
3 - FRONT CABLE STRAND
4 - AUTO-ADJUST LOCKOUT PIN
5 - INDICATOR LAMP SWITCH

5 - 66

BRAKES - BASE

RS

CABLE - PARKING BRAKE FRONT (Continued)

(4) Install cable strand button into the reel on the

parking brake lever mechanism (Fig. 106).

(5) Install the front parking brake cable floor pan

seal into the hole in the floor pan. The seal flange
should be flush with the floor pan (Fig. 102).

(6) Reposition the carpeting back down on the

floor.

(7) Install the left front kick panel.
(8) Install the left front door sill molding.
(9) Raise and support the vehicle.
(10) Pass the end of the cable through the hole in

the end of the intermediate bracket (Fig. 104). Press
the cable housing retainer through the hole until the
fingers on the retainer lock it into place.

(11) Attach the front cable to the routing clips fas-

tened to the underbody of the vehicle (Fig. 104).

(12) Clamp an appropriate pair of locking pliers on

the front cable strand approximately 25 mm (1 inch)
forward of the button (Fig. 107).

(13) Pull straight back on the front cable button

(and pliers) and properly attach the equalizer to all
three parking brake cables (Fig. 103).

(14) Remove the locking pliers from the front park-

ing brake cable and allow the automatic self-adjust-
ing mechanism in the lever to take up any slack.

(15) Lower the vehicle.
(16) Apply and release park brake pedal 1 time.

This will seat the parking brake cables.

INSTALLATION - EXPORT

(Refer to 5 - BRAKES - BASE/PARKING BRAKE/

LEVER - INSTALLATION)

CABLE - PARKING BRAKE
INTERMEDIATE

REMOVAL

(1) Raise

and

support

the

vehicle.

(Refer

to

LUBRICATION

&

MAINTENANCE/HOISTING

-

STANDARD PROCEDURE).

(2) Manually lock out the automatic self-adjusting

mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
izer,

do

not

remove

the

locking

pliers

until

reinstallation of the cable is complete.

(3) Remove the intermediate parking brake cable

from the parking brake cable equalizer (Fig. 108).

(4) Remove the locking nut securing the interme-

diate cable housing to the side bracket on the frame
rail (Fig. 108).

(5) Remove the intermediate parking brake cable

from the cable connector attaching it to the right
rear parking brake cable (Fig. 109). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 109).

(6) If the vehicle is a short-wheel-base model, it

will be necessary to loosen and lower the fuel tank
far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).

(7) Remove the intermediate parking brake cable

from the side brackets and vehicle.

Fig. 107 Location To Grasp Cable At

Fig. 108 Parking Brake Cable Attachment To

Equalizer

1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE

RS

BRAKES - BASE

5 - 67

CABLE - PARKING BRAKE FRONT (Continued)

INSTALLATION

(1) Install the ends of the park brake cables

through the frame rails and into the side brackets.

(2) Install the locking nuts at each end of the cable

and securely tighten (Fig. 108) (Fig. 109).

(3) If the vehicle is a short-wheel-base model, it

will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL

DELIVERY/FUEL

TANK

-

INSTALLATION).

(4) Install the intermediate parking brake cable on

the cable connector at the right rear parking brake
cable (Fig. 109).

(5) Install the intermediate park brake cable on

the cable equalizer (Fig. 108).

(6) Remove the locking pliers from the front park

brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables.

(7) Install and position the foam collar on the

parking brake cable to prevent it from rattling
against the vehicle’s floor.

(8) Lower the vehicle and apply the park brake

pedal 1 time, this will seat the park brake cables.

CABLE - PARKING BRAKE
REAR

REMOVAL

REMOVAL - RIGHT REAR

(1) Raise

and

support

the

vehicle.

(Refer

to

LUBRICATION

&

MAINTENANCE/HOISTING

-

STANDARD PROCEDURE).

(2) Remove rear tire and wheel assembly.

(3) Remove rear brake drum from the rear wheel

of the vehicle requiring service to the rear park
brake cable.

(4) Create slack in the rear parking brake cables

by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it.
At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger
bracket (Fig. 110).

(5) Disconnect the right rear parking brake cable

from the connector on the intermediate cable (Fig.
111).

(6) To remove the right parking brake cable hous-

ing from the body bracket, slide a 14 mm box end

Fig. 109 Intermediate Cable Attachment To Right

1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE

Fig. 110 Locking Out Automatic Adjuster

1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS

Fig. 111 Right Rear Cable Connection To

Intermediate Cable

1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE

5 - 68

BRAKES - BASE

RS

CABLE - PARKING BRAKE INTERMEDIATE (Continued)