Chrysler Caravan/Voyager/Town and Country 1996-1999

Proportioning Valve

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REMOVAL & INSTALLATION



Non-ABS (Height Sensing Proportioning Valve)

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Remove the four lines from the valve ...



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Fig. Fig. 2: ... unbolt the valve from the bracket, and unhook the actuator

  1. 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.
  2.  
  3. Raise and safely support the vehicle securely on jackstands.
  4.  

To prevent possible hydraulic system contamination, thoroughly clean the proportioning valve and brake tubes. Use MOPAR® Brake Parts Cleaner, or an equivalent solvent.

  1. Remove the 4 brake lines from the inlet and outlet ports of the proportioning valve.
  2.  
  3. Loosen the 2 retaining bolts, then remove the proportioning valve from the proportioning valve mounting bracket.
  4.  
  5. Remove the hooked end of the proportioning valve actuator from the isolator bushing on the lever of the height proportioning valve.
  6.  

To install:
  1. Install the hooked end of the actuator on the proportioning valve lever. Be sure that the isolator bushing on the lever of the proportioning valve is fully seated in the hook of the actuator.
  2.  

When installing the height sensing proportioning valve onto the mounting bracket, be sure that the proportioning valve shield is installed between the valve and the mounting bracket.

  1. Place the proportioning valve assembly into position on the mounting bracket. Install the mounting bolts and tighten to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the chassis brake lines into the proportioning valve assembly. Tighten the brake line fittings to 12 ft. lbs. (16 Nm).
  4.  
  5. Adjust the proportioning valve actuator according to the following steps:
    1. Remove the rear wheels.
    2.  
    3. Using an appropriate jack, support the rear axle prior to the removal of the track bar and shock absorber bolts from the rear axle.
    4.  
    5. Separate the track bar from the rear axle.
    6.  
    7. Separate both of the shock absorbers from the rear axle.
    8.  

  6.  

When lowering the rear axle, be sure that the leaf springs do not make contact with the hoist, which will limit the downward movement of the axle. If this happens, an improper adjustment of the actuator may result.

  1. Loosen, but do not remove, both of the leaf spring-to-front spring hanger pivot bolts.
  2.  
  3. Lower the rear axle so it is at its farthest point of downward movement.
  4.  
  5. Loosen the adjustment nut on the actuator.
  6.  
  7. Be sure that the hooked end of the actuator is correctly seated in the clip on the proportioning valve lever and that the clip is positioned correctly on the lever of the proportioning valve.
  8.  
  9. Pull the proportioning valve actuator housing toward the spring hanger until the proportioning valve lever bottoms on the proportioning valve body. Hold the proportioning valve actuator in this position while tightening the adjusting nut to 45 inch lbs. (5 Nm). Proportioning valve adjustment is now complete.
  10.  
  11. Connect the shock absorbers and track bar to the rear axle. Install, but do not tighten any of these mounting bolts at this time.
  12.  
  13. Install the wheels.
  14.  

  1. Bleed the brake system.
  2.  
  3. Lower the vehicle. Be sure that the suspension is supporting the full weight of the vehicle.
  4.  
  5. Tighten the following bolts to these specifications:

    Spring-to-front hanger pivot bolts-115 ft. lbs. (156 Nm)
     
    Shock absorber mounting bolts-75 ft. lbs. (101 Nm)
     
    Track bar mounting bolt-70 ft. lbs. (95 Nm)
     

  6.  
  7. Carefully road test the vehicle to verify proper brake system operation.
  8.  

 
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