Chrysler Caravan/Voyager/Town and Country 1996-1999

Controller Anti-lock Brakes (CAB)

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REMOVAL & INSTALLATION



1996 Vehicles

See Figures 1 and 2



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Fig. Fig. 1: on 1996 vehicles, the CAB unit is located under the instrument panel near the heater A/C duct



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Fig. Fig. 2: The CAB bracket is held in place by two nuts

The CAB is mounted under the instrument panel on the side of the brake pedal bracket toward the center of the vehicle.

  1. Turn the ignition switch OFF .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the retaining bolt, then unplug the 60-pin wiring harness connector from the CAB.
  6.  
  7. Remove the 2 nuts attaching the CAB mounting bracket to the brake pedal bracket, then remove the CAB from the vehicle.
  8.  

To install:
  1. Install the CAB module and bracket assembly onto the brake pedal bracket. Secure the CAB in place with the 2 mounting nuts. Tighten the mounting nuts to 21 ft. lbs. (28 Nm).
  2.  
  3. Attach the 60-way connector to the CAB by hand as far as possible, then use the CAB connector retaining bolt to fully seat the wiring harness connector into the CAB.
  4.  
  5. Tighten the 60-way connector retaining bolt and tighten to 35 inch lbs. (4 Nm).
  6.  
  7. Connect the negative battery cable.
  8.  

1997-99 Vehicles

See Figures 3, 4 and 5



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Fig. Fig. 3: On 1997-99 vehicles, the CAB (integrated with the Hydraulic Control Unit, or HCU) is located on the front suspension cradle



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Fig. Fig. 4: Once the HCU is removed, the CAB can be removed



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Fig. Fig. 5: The CAB can be separated from the HCU by removing the 4 mounting screws

The CAB is mounted to the bottom of the Hydraulic Control Unit (HCU).

  1. Disconnect the negative battery cable.
  2.  
  3. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
  4.  
  5. Raise and safely support the vehicle securely on jackstands.
  6.  
  7. Disengage the 25-way wiring harness connector from the CAB by grasping the lock on the connector and pulling it out from the connector as far as it will go. This will remove the connector out from the CAB socket.
  8.  


WARNING
Do not apply a 12 volt power source to any terminals of the 25-way connector when it is disengaged.

  1. To prevent possible hydraulic system contamination, thoroughly clean the HCU and brake tubes. Use MOPAR® Brake Parts Cleaner, or an equivalent solvent.
  2.  
  3. Label and disconnect the chassis brake tubes from the inlet and outlet ports of the HCU.
  4.  
  5. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
  6.  
  7. Remove the HCU and the mounting bracket as a unit from the vehicle.
  8.  
  9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket.
  10.  
  11. Unplug the pump motor wiring harness from the CAB.
  12.  
  13. Loosen the 4 mounting bolts, then separate the CAB from the valve block of the HCU.
  14.  

To install:
  1. Place the CAB in position against the valve block of the HCU. Install and tighten the 4 mounting bolts to 17 inch lbs. (2 Nm).
  2.  
  3. Plug the pump motor wiring harness into the CAB.
  4.  
  5. Install the HCU onto the mounting bracket and tighten the 3 mounting bolts to 97 inch lbs. (11 Nm).
  6.  
  7. Place the HCU and mounting bracket assembly into position on the front suspension crossmember and tighten the mounting bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. Install the chassis brake tubes into their correct port locations on the HCU valve block. Tighten the brake tube fittings to 13 ft. lbs. (17 Nm).
  10.  
  11. Install the 25-way connector into the CAB socket. Install the connector in the following manner:
    1. Position the connector into the CAB socket and carefully push it down as far as it will go.
    2.  
    3. Once the connector is fully seated into the socket, push in the connector lock as far as it will go. This pulls the connector into the socket which locks it in the installed position.
    4.  

  12.  
  13. Install the routing clips onto the brake tubes.
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Remove the brake pedal positioning tool from the vehicle.
  20.  
  21. Bleed the base brake system and the ABS hydraulic system.
  22.  
  23. Road test the vehicle to ensure proper operation of the base and ABS systems.
  24.  

 
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