Chrysler Caravan/Voyager/Town and Country 1996-1999

Cables

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REMOVAL & INSTALLATION



Front Cable

See Figures 1, 2 and 3



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Fig. Fig. 1: Before removing the park brake cable, lock out the self-adjusting mechanism



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Fig. Fig. 2: Disconnecting the front cable from the intermediate and left rear parking brake cables

  1. Raise and safely support the vehicle.
  2.  
  3. Manually lock out the automatic self-adjuster mechanism of the parking brake pedal assembly.
  4.  
  5. Remove the intermediate brake cable and the left rear parking brake cable from the parking brake cable equalizer.
  6.  
  7. Remove the front parking brake cable housing retainer from the body outrigger bracket. Use a hose clamp or a 14mm box wrench to compress the fingers of the cable housing retainer.
  8.  
  9. Lower the vehicle to the ground.
  10.  
  11. Remove the left front door sill molding from the vehicle.
  12.  
  13. Remove the left front kick panel for access to the parking brake cable and parking brake pedal assembly.
  14.  
  15. Lift the floor mat/carpet for access to the parking brake cable and vehicle floor pan. Remove the seal and the cable from the floor pan.
  16.  
  17. Pull the cable forward and disconnect from the lever clevis. Tap the cable housing end fitting out of the pedal assembly bracket.
  18.  



Click image to see an enlarged view

Fig. Fig. 3: After the front cable is disconnected, lift the carpet and feed the cable through the floor pan and disconnect it from the pedal assembly

  1. Remove the parking brake cable retainer from the parking brake pedal assembly bracket.
  2.  
  3. Pull the cable assembly out of the vehicle through the floor pan hole.
  4.  

To install:
  1. Feed the new cable through the floor pan hole.
  2.  
  3. Route the brake cable end button through the hole in the parking brake pedal assembly bracket.
  4.  
  5. Install the brake cable retainer onto the parking brake cable. Install the parking brake cable retainer into the park brake pedal assembly bracket.
  6.  
  7. Install the parking brake cable end into the retainer previously installed into the parking brake pedal bracket.
  8.  
  9. Install the front parking brake cable end button into the clevis of the parking brake pedal mechanism.
  10.  
  11. Install the floor pan seal into the hole in the floor pan. Install the seal so the flange on the seal is flush with the floor pan. Place the floor mat/carpet back down on the floor.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Install the cable and housing into the body outrigger bracket. Be sure the housing retainer fingers lock the housing firmly into position.
  16.  

  1. Connect the parking brake cables to the parking brake cable equalizer.
  2.  
  3. Lower the vehicle to the ground.
  4.  
  5. Engage the automatic self-adjusting mechanism.
  6.  
  7. Apply and release the parking brake pedal one time only. This will correctly seat the parking brake cables.
  8.  
  9. Road test the vehicle and check for proper brake operation.
  10.  

Intermediate Parking Brake Cable

See Figures 1, 2 and 4



Click image to see an enlarged view

Fig. Fig. 4: Disconnecting the intermediate cable from the right rear parking brake cable

  1. Raise and safely support the vehicle.
  2.  
  3. Manually lock out the automatic self-adjuster mechanism of the parking brake pedal assembly.
  4.  
  5. Remove the intermediate brake cable and the left rear parking brake cable from the parking brake cable equalizer.
  6.  
  7. Disconnect the intermediate parking brake cable from the cable connector attaching it to the right rear parking brake cable.
  8.  
  9. Remove the intermediate parking brake cable from the cable guides on the vehicle frame rail.
  10.  

To install:
  1. Install the ends of the parking brake cables through the parking brake cable guides.
  2.  
  3. Connect the intermediate parking brake cable to the cable connector at the right rear parking brake cable.
  4.  
  5. Connect the intermediate parking brake cable to the parking brake cable equalizer.
  6.  
  7. Engage the automatic self-adjusting mechanism.
  8.  
  9. If equipped, install and properly position the foam collar on the parking brake cable to prevent the brake cable from rattling against the floor of the vehicle.
  10.  
  11. Lower the vehicle to the ground.
  12.  
  13. Apply and release the parking brake pedal one time only. This will correctly seat the parking brake cables.
  14.  
  15. Road test the vehicle and check for proper brake operation.
  16.  

Right Rear Parking Brake Cable

See Figures 1, 2, 4, 5, 6 and 7



Click image to see an enlarged view

Fig. Fig. 5: Park brake detail-models with rear disc brakes



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Fig. Fig. 6: A 1/2inch box end wrench can be used to remove the cable from the adapter on models equipped with disc brakes

  1. Raise and safely support the vehicle. Remove the right rear wheel.
  2.  
  3. Remove the right rear wheel brake drum.
  4.  
  5. Manually lock out the automatic self-adjuster mechanism of the parking brake pedal assembly as follows:
    1. Position the park brake pedal in the fully released position.
    2.  
    3. From below the vehicle, firmly grasp the exposed section of the front parking brake cable and pull downward until all free movement is removed from the parking brake cable.
    4.  
    5. Install a pair of locking pliers onto the parking brake cable just rearward of the second body outrigger bracket.
    6.  

  6.  
  7. Disconnect the right rear parking brake cable from the connector on the intermediate parking brake cable.
  8.  
  9. Remove the right parking brake cable housing from the body bracket by slipping a 14mm box wrench over the end of the brake cable retainer to compress the retaining fingers.
  10.  
  11. Remove the brake shoes from the brake support plate.
  12.  
  13. Disconnect the cable from the parking brake actuator lever in the brake shoe assembly. Compress the cable housing retainer lock with a mini-hose clamp or 14mm box wrench and pull the cable from the brake support plate.
  14.  

To install:
  1. Install the new cable through the brake support plate. Engage the cable housing retainer fingers until they lock the cable housing firmly into place.
  2.  
  3. Attach the cable to the parking brake actuator lever on the brake shoe assembly. Install the brake shoes, brake drum, and rear wheel. Torque the lug nuts, in sequence, to 95 ft. lbs. (129 Nm).
  4.  
  5. Install the brake cable housing retainer into the body bracket, making sure cable housing retainer fingers lock the cable housing firmly into place.
  6.  
  7. Connect the right rear parking brake cable to the connector on the end of the intermediate parking brake cable.
  8.  
  9. Remove the locking pliers from the front parking brake cable. The parking brake cables will automatically adjust.
  10.  
  11. Lower the vehicle.
  12.  
  13. Apply and release the parking brake pedal one time only. This will correctly seat the parking brake cables.
  14.  
  15. Road test the vehicle and check for proper brake operation.
  16.  

Left Rear Parking Brake Cable

See Figures 1, 2, 7, and 8



Click image to see an enlarged view

Fig. Fig. 7: Using a 14mm box end wrench to remove the cable from the brake support plate



Click image to see an enlarged view

Fig. Fig. 8: Removing the left rear parking brake cable from the body bracket

  1. Raise and safely support the vehicle. Remove the left rear wheel.
  2.  
  3. Remove the left rear wheel brake drum.
  4.  
  5. Manually lock out the automatic self-adjuster mechanism of the parking brake pedal assembly as follows:
    1. Position the park brake pedal in the fully released position.
    2.  
    3. From below the vehicle, firmly grasp the exposed section of the front parking brake cable and pull downward until all free movement is removed from the parking brake cable.
    4.  
    5. Install a pair of locking pliers onto the parking brake cable just rearward of the second body outrigger bracket.
    6.  

  6.  
  7. Disconnect the left rear parking brake cable from the parking brake cable equalizer.
  8.  
  9. Remove the left parking brake cable housing from the body bracket by slipping a 14mm box wrench over the end of the brake cable retainer to compress the retaining fingers. A small aircraft type hose clamp can also be used.
  10.  
  11. Remove the brake shoes from the brake support plate.
  12.  
  13. Disconnect the cable from the parking brake actuator lever in the brake shoe assembly. Compress the cable housing retainer lock with a mini-hose clamp or 14mm box wrench and pull the cable from the brake support plate.
  14.  

To install:
  1. Install the new cable through the brake support plate. Engage the cable housing retainer fingers until they lock the cable housing firmly into place.
  2.  
  3. Attach the cable to the parking brake actuator lever on the brake shoe assembly. Install the brake shoes, brake drum, and rear wheel. Torque the lug nuts, in sequence, to 95 ft. lbs. (129 Nm).
  4.  
  5. Install the brake cable housing retainer into the body bracket, making sure cable housing retainer fingers lock the cable housing firmly into place.
  6.  
  7. Connect the left rear parking brake cable end to the parking brake cable equalizer bracket.
  8.  
  9. Remove the locking pliers from the front parking brake cable. The parking brake cables will automatically adjust.
  10.  
  11. Lower the vehicle.
  12.  
  13. Apply and release the parking brake pedal one time only. This will correctly seat the parking brake cables.
  14.  
  15. Road test the vehicle and check for proper brake operation.
  16.  

ADJUSTMENT



1996-97 Models

CAUTION
The self-adjusting feature of this parking brake lever assembly contains a clockspring loaded to approximately 8 pounds. Care must be taken to prevent excessive jarring of the assembly. Do not release the self-adjuster lockout device before installing cables into the equalizer. Keep hands out of the self-adjuster sector and pawl area. Failure to observe this warning in handling this mechanism could lead to serious injury.

MANUAL LOCK-OUT OF AUTOMATIC SELF-ADJUSTER
  1. Be sure the parking brake pedal (system) is in the fully released position.
  2.  
  3. From underneath the vehicle, have an assistant grasp the exposed section of the front parking brake cable and pull downward until all free movement is eliminated from the cable.
  4.  
  5. Install a 3 / 16 in. drill bit into the clockspring and position against the parking brake pedal arm.
  6.  

ENGAGING THE AUTOMATIC SELF-ADJUSTER
  1. Be sure all the parking brake cables are correctly installed, clipped as required and properly connected.
  2.  
  3. Using a pair of pliers, firmly grasp the lock pin previously installed in the parking brake pedal mechanism.
  4.  
  5. Remove the lock pin from the parking brake pedal mechanism by pulling it firmly and rapidly from the park brake mechanism. This will allow the mechanism to correctly adjust the parking brake cables.
  6.  
  7. Apply and release the parking brake pedal one time. This will seat the parking brake cables. The rear wheels should rotate freely without dragging.
  8.  

1998-99 Models

The parking brake pedal mechanism utilized in this vehicle is designed so that the automatic adjuster is not required to be locked out when servicing the parking brake pedal or cables.

This mechanism is designed so that the adjuster mechanism will rotate only 1 / 2 turn when the tension is released from the parking brake cable. This eliminates the need to lock out the automatic adjuster when servicing the parking brake pedal mechanism and cables.

Use the following procedures to release the tension from the parking brake cables and the automatic adjuster in the pedal mechanism.

LOCK-OUT OF AUTOMATIC ADJUSTER
  1. From underneath the vehicle, have an assistant grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the cable in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket.
  2.  
  3. Disconnect the left rear and intermediate parking brake cables from the parking brake cable equalizer.
  4.  
  5. Remove the equalizer from the front parking brake cable.
  6.  
  7. Remove the locking pliers from the front parking brake cable. This will enable the adjuster in the parking brake pedal mechanism to rotate around to its stop. This will relieve the tension from the adjuster and front parking brake cable.
  8.  

ENGAGING THE AUTOMATIC ADJUSTER RESET
  1. From underneath the vehicle, have an assistant grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the cable in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket.
  2.  
  3. Install the equalizer onto the front parking brake cable.
  4.  
  5. Connect the left rear and intermediate parking brake cables into the correct locations on the parking brake cable equalizer.
  6.  
  7. Remove the locking pliers from the front parking brake cable. This will enable the adjuster in the parking brake pedal mechanism to tension the parking brake cables.
  8.  
  9. Apply and release the parking brake pedal one time. This will seat the parking brake cables and enable the automatic adjuster in the parking brake pedal mechanism to correctly tension the parking brake cables.
  10.  

 
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