Chrysler Caravan/Voyager/Town and Country 1996-1999

Wheel Speed Sensors

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REMOVAL & INSTALLATION



One of the primary inputs to the ABS system is from the wheel speed sensors. There is a sensor at each wheel that reads magnetic impulses from a toothed gear-like tone wheel. The sensors are easily damaged and must be handled with care. Make sure the wheel sensor surfaces are clean since they are magnetic and attract metal chips and debris. Use care when removing, installing and routing the sensor wiring. The wiring must be correctly installed to avoid ABS problems later.

Front Wheel Sensor

See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Remove the two screws that secure the mounting bracket and grommet retainer ...



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Fig. Fig. 2: ... then pull the grommet down ...



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Fig. Fig. 3: ... and unplug the connector



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Fig. Fig. 4: Next, remove the bolt that secures the wheel sensor ...



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Fig. Fig. 5: ... and carefully remove it from the steering knuckle



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Fig. Fig. 6: The wheel sensor assembly can now be removed from the vehicle

  1. Disconnect negative battery cable.
  2.  
  3. Carefully raise and safely support the vehicle. Remove the front wheel.
  4.  
  5. Remove the 2 mounting screws that attach the front channel bracket and grommet retainer to the outer vehicle frame rail.
  6.  
  7. Pull the speed sensor cable grommet and wiring connector through the hole in the strut tower. Disconnect the vehicle wiring harness connector from the speed sensor connector. Be careful not to damage the pins on the connector.
  8.  
  9. Remove the bolt that mounts the speed sensor head to the steering knuckle.
  10.  
  11. Gently remove the speed sensor head from the steering knuckle.
  12.  


WARNING
Do not remove the speed sensor with pliers for any reason. If the speed sensor has seized, due to corrosion, remove it with a small mallet and punch. Lightly tap the edge of the sensor ear, rocking the sensor from side to side until it is free.

  1. Remove the speed sensor cable grommets from the retaining bracket.
  2.  
  3. Remove the wheel speed sensor from the vehicle.
  4.  

To install:
  1. Install the speed sensor head into the steering knuckle. Install the mounting screw and torque to 105 inch lbs. (12 Nm).
  2.  
  3. Inspect the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. The air gap must be less than the maximum allowable tolerance of 0.047 inch (1.2mm).
  4.  

Correct system operation depends on the wheel speed sensor cables being installed properly. Be sure the sensor cables are installed in the retainers. Failure to do this could result in cable over extension and/or contact with moving parts. This could result in an open circuit and/or false sensor readings.

  1. Install the speed sensor wiring grommets into the intermediate retaining bracket on the strut assembly. Be sure the sensor cable is routed correctly to the strut assembly on the rearward side of the stabilizer bar link.
  2.  
  3. Install the 2 mounting bolts that attach the channel bracket to the vehicle frame. Torque the 2 bolts to 95 inch lbs. (11 Nm).
  4.  
  5. Install the channel bracket and grommet retainer onto the vehicle frame rail. Be careful not to pinch the speed sensor cable under the channel bracket.
  6.  
  7. Connect the wheel speed sensor connector to the vehicle wiring harness connector. Be sure to securely latch the connector locking tab and seat the connector properly.
  8.  
  9. Insert the sensor cable and cable grommet into the hole in the strut tower.
  10.  
  11. Install the front wheel and lug nuts. Tighten the wheel lug nuts in a star pattern sequence and torque the nuts to half specification. Then repeat the lug nut torquing sequence to full specified torque of 95 ft. lbs. (129 Nm).
  12.  
  13. Lower the vehicle. Reconnect the negative battery cable.
  14.  
  15. Road test the vehicle to check the operation of the ABS and base brake systems.
  16.  

Rear Wheel Sensor

See Figures 7, 8, 9 and 10



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Fig. Fig. 7: Rear wheel speed sensor location (vehicles with drum brakes)



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Fig. Fig. 8: Rear wheel speed sensor location (vehicles with disc brakes)



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Fig. Fig. 9: The rear wheel speed sensor cable routing detail



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Fig. Fig. 10: Remove the grommet in the floor pan to access the speed sensor cable connector

  1. Disconnect the negative battery cable.
  2.  
  3. Carefully raise and safely support the vehicle. Remove the rear wheel.
  4.  
  5. Remove the speed sensor cable grommet, then the wiring harness through the hole in the vehicle floor pan. Do NOT pull on the speed sensor wiring when removing the grommet from the underbody.
  6.  
  7. Disconnect the speed sensor wiring connector from the vehicle wiring harness. Be careful not to damage the pins of the wiring connectors. Also inspect the connectors for any signs of previous damage.
  8.  
  9. Remove the speed sensor wiring from the rear brake flex hose routing clips. Be careful to NOT damage the routing clips on the rear brake flex hose. The routing clips are molded to the brake hoses and if they are damaged, the brake flex hoses will require replacement.
  10.  
  11. If removing the right side rear speed sensor, remove the speed sensor cable grommet from the axle flange, brake tube clip and routing clip from the track bar bracket on the axle.
  12.  
  13. Remove the 2 rear speed sensor cable/brake tube routing clips and then unclip the speed sensor cable from the routing clips on the rear brake tube.
  14.  
  15. Remove the speed sensor head mounting bolt from the rear bearing. Remove the wheel speed sensor head from the rear bearing assembly.
  16.  


WARNING
Do not remove the wheel speed sensor with pliers for any reason. If the speed sensor has seized, due to corrosion, remove it with a hammer and punch. Lightly tap the edge of the sensor ear, rocking the sensor from side to side until it is free.

  1. Remove the wheel speed sensor from the vehicle.
  2.  

To install:
  1. Install the wheel speed sensor head into the rear wheel bearing assembly. Be sure the plastic, anti-rotation pin is fully seated in wheel bearing flange before installing the mounting bolt. Install the mounting bolt and torque to 105 inch lbs. (12 Nm).
  2.  
  3. Inspect the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. The air gap must be less than the maximum allowable tolerance of 0.047 inch (1.2mm).
  4.  
  5. Install the 2 routing brackets that secure the speed sensor cable and brake tube to the rear axle. The speed sensor cable must be routed underneath the brake tube. Be careful not to damage the brake hose routing clips.
  6.  
  7. Install the speed sensor cable into the rear brake flex hose routing clips.
  8.  
  9. If installing the right rear speed sensor cable, install the cable grommet onto the rear axle brake flex hose bracket.
  10.  


WARNING
The left and right rear wheel speed sensor connectors are keyed differently. Therefore, when connecting a speed sensor cable to a vehicle wiring harness, do NOT force the connectors together, or damage to the connectors will result.

  1. Connect the speed sensor wiring connector to the vehicle wiring harness and install the sensor cable grommet back into the wiring access hole on the vehicle underbody. Be sure the speed sensor connector is fully seated and locked into the vehicle wiring harness. Be sure the speed sensor cable grommet is fully seated into the vehicle underbody wiring access hole.
  2.  
  3. Install the wheel and lug nuts. Tighten the wheel lug nuts in a star pattern sequence and torque the nuts to half specification. Then repeat the lug nut tightening sequence to full specified torque of 95 ft. lbs. (129 Nm).
  4.  
  5. Lower the vehicle to the ground.
  6.  
  7. Reconnect the negative battery cable. Road test the vehicle and check for proper base and ABS braking system operation.
  8.  

TESTING



  1. Inspect the sensor and its connector. If the sensor looks damaged or connector looks disengaged, repair it as necessary.
  2.  
  3. With the ignition key turned OFF , disengage the wheel speed sensor connector. Inspect the condition of the terminals and repair as necessary.
  4.  
  5. Using an ohmmeter, measure the resistance between the wheel speed sensor connector terminals on the sensor side.
  6.  
  7. The resistance should measure 900-1300 ohms. If the resistance measures outside this value, replace the wheel speed sensor.
  8.  
  9. Then, measure the resistance between either one of the wheel speed sensor pins and ground on the sensor side.
  10.  
  11. If the resistance measures below 15k ohms, replace the wheel speed sensor.
  12.  

 
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