Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 166
Fig.
1
Parking
Brake
Cable
Routing
F
.W
.D.
&
A.W
.D.
.
BRAKES
5 - 47
SERVICE PROCEDURES
ADJUSTING PARKING BRAKE
The service brakes must be properly adjusted before
adjusting the parking brake.
Remove plastic cover by pressing in the fingers of the
cover through holes in bracket (Fig. 1).
Before loosening cable adjusting nut, clean threads
with brush and lubricate with grease. Do not use a
metal wire brush because it will scratch off plating and
coating.
Release the parking brake pedal then back off cable
adjusting nut so there is slack in the cable.
Push parking brake pedal all the way to the floor.
Mark bent nail adjuster approximately 6 mm (1/4
inch) from bracket (Fig. 2).
Tighten adjusting nut until mark moves into align-
ment with edge of bracket. Important: Replace bent
nail with a new part if nail end hook has moved all the
way to the bracket.
Replace plastic cover and tethered plug.
Apply and release the parking brake to see that the
rear wheels rotate freely without dragging.
CAUTION: The threaded rod, washer and nut of the
adjuster are made of stainless steel. Do not use a
non-stainless steel washer or nut because an electro-
chemical reaction could occur. This could cause
highly accelerated corrosion leading to failure of the
washer or nut.
PARKING BRAKE PEDAL ASSEMBLY
REMOVE
Loosen cable adjusting nut and disconnect front
cable from adjuster (Fig. 2).
Remove sill molding/cowl side scuff panel and steer-
ing column cover. Increase access by removing fuse
box, if required.
Disconnect the electrical connector for the brake
light switch. Remove pedal assembly to body attaching
bolts (Fig. 3).
Remove front cable strand button from clevis. Tap
cable housing end fitting out of assembly (Fig. 3).
INSTALL
Install cable retainer into pedal assembly bracket
(Fig. 3).
Install cable into retainer and strand button into
clevis (Fig. 3).
Bolt pedal assembly into place. Tighten pedal assem-
bly attaching bolts to 28 N
Im (250 in. lbs.). Install
electrical connector for the brake light switch.
Install fuse box, steering column cover and sill
molding/cowl side scuff panel.
Connect front cable and adjust parking brake (Fig.
2). See Adjusting Parking Brake in this section of the
service manual for the correct adjusting procedure.
FRONT PARKING BRAKE CABLE
REMOVE
Loosen cable adjusting nut and disengage front cable
from adjuster. Remove cable housing retainer from
anchor bracket, by sliding a 14 mm box wrench over
cable retainer and compressing the three fingers. Al-
ternate method is to use an aircraft type hose clamp
and screwdriver. This is similar to the method shown
for removing the parking brake cable from the support
plate (Fig. 4).
Remove cable guide brackets from frame rail and
loosen cable housing at pedal assembly.
Fig. 2 Equalizer/Bent Nail Adjuster Assembly
Fig. 3 Parking Brake Pedal Remove And Install
5 - 48
BRAKES
.
Lift floor mat for access to floor pan and force seal out
of hole (into vehicle).
Pull cable end forward and disconnect button from
clevis. Tap cable housing end fitting out of pedal
assembly bracket.
Pull cable assembly through hole.
INSTALL
Pass cable assembly through hole in floor from inside
vehicle (Fig. 3).
Install cable retainer into brake pedal assembly
bracket and then install cable housing end fitting into
retainer.
Engage cable strand button into clevis.
Install floor pan seal and floor mat.
Insert brake cable and housing into anchor bracket
making certain that housing retainer fingers lock the
housing firmly into place.
Install cable guide brackets.
Assemble adjuster to front cable.
Adjust parking brake.
REAR PARKING BRAKE CABLE
REMOVE
With vehicle jacked up on suitable hoist remove
wheel and tire.
Back off cable adjusting nut to provide slack and
disconnect rear cable from equalizer bracket.
To remove cable from anchor bracket. Remove cable
housing retainer from anchor bracket by sliding a 14
mm box wrench over retainer end compressing the
three fingers. Alternate method is to use an aircraft
type hose clamp and screwdriver. This is similar to the
method shown for removing the brake cable from the
brake support plate (Fig. 4).
Remove cable wrap-around clips where applicable.
Disconnect cable guide wires where applicable.
Remove brake drum and hub from spindle.
Disconnect cable from brake internal lever.
Remove park brake cable housing retainer from the
brake support plate. Use the same method for remov-
ing cable retainer from brake support plate as was
used above for the cable anchor bracket.
INSTALL
Insert park brake cable into hole in the brake sup-
port plate. Attach park brake cable to park brake
internal lever attached to brake shoe.
Insert cable housing retainer into brake support
plate making certain that cable housing retainer fin-
gers lock the housing and retainer firmly into place.
Install brake drum, wheel and tire.
Insert cable housing retainer into anchor bracket
making certain that cable housing retainer fingers lock
the housing firmly into place.
Attach cable guide wires and wrap-around clips
where applicable.
Connect equalizer bracket.
Adjust service brakes and then adjust parking brake.
MASTER CYLINDER
INDEX
page
page
General Information
. . . . . . . . . . . . . . . . . . . . . . . 49
Reservoir Replacement
. . . . . . . . . . . . . . . . . . . . 50
Service Procedures
. . . . . . . . . . . . . . . . . . . . . . . 50
GENERAL INFORMATION
The tandem master cylinder (Fig. 1) has a glass
reinforced nylon reservoir and an anodized aluminum
body.
CAUTION: Do not hone the bore of the cylinder, as
this will remove the anodized surface.
The master cylinder reservoir is indexed to prevent
installation in the wrong direction. The cap dia-
phragms are slit to allow pressure to equalize.
The secondary outlet tube from the master cylinder
is connected to the proportioning valve mounted under
the master cylinder. The front part of this valve sup-
plies the right rear and left front brakes.
Fig. 4 Removing Brake Cable from Brake Support
Plate
.
BRAKES
5 - 49
The primary outlet tube from the master cylinder is
also connected to the proportioning valve. The back
part of this valve supplies the right front and left rear
brakes.
RESERVOIR REPLACEMENT
See Master Cylinder Removal.
Clean master cylinder housing and fluid reservoir.
Remove caps and empty brake fluid from reservoir.
Position master cylinder in vise.
Rock fluid reservoir from side to side and remove
from master cylinder housing (Fig. 2).
Remove master cylinder housing-to-fluid reservoir
grommets (Fig. 3).
Install new master cylinder housing-to-fluid reser-
voir grommets in master cylinder housing.
Lubricate fluid reservoir mounting areas with brake
fluid. Place reservoir in position over grommets. Seat
fluid reservoir onto master cylinder housing, by apply-
ing downward pressure while using a side to side
rocking motion until reservoir is fully seated in grom-
mets.
Be sure reservoir is positioned properly. All lettering
should be properly read from the left side of the master
cylinder.
Make sure bottom of reservoir touches top of grom-
met.
SERVICE PROCEDURES
MASTER CYLINDER
REMOVE
Disconnect primary and secondary brake tubes from
master cylinder housing. Install plugs at brake tube
outlets.
Remove 2 nuts (Fig. 4) attaching master cylinder
housing to power brake booster unit.
Fig. 1 Aluminum Master Cylinder
Fig. 2 Removing Reservoir
Do not pry fluid reser-
voir off master cylinder housing using a tool, dam-
age to the fluid reservoir may result.
Fig. 3 Removing Grommets
Fig. 4 Master Cylinder Mounting
5 - 50
BRAKES
.
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