Chrysler Caravan/Voyager/Town n Country 1984-1995

Hydraulic Assembly

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Hydraulic assembly mounting and under dash connections


CAUTION
This brake system uses a hydraulic accumulator which, when fully charged, contains brake fluid at very high pressure. Before disconnecting any hydraulic lines, hoses or fittings be certain that the accumulator pressure is completely relieved. Failure to depressurize the accumulator may result in personal injury and/or vehicle damage.

  1. Depressurize the brake system.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the windshield washer fluid bottle.
  6.  
  7. Disengage all electrical connectors at the hydraulic assembly.
  8.  
  9. Use a syringe to remove as much fluid as possible from the reservoir.
  10.  
  11. Unfasten and remove the banjo bolt holding the high pressure hose to the hydraulic assembly.
  12.  
  13. Remove the hose from the steel tube and cap the tube.
  14.  
  15. Disconnect the brake lines from the hydraulic assembly.
  16.  
  17. Use a small flat tool to release the retainer clip on the brake pedal pin. The center tang on the clip must be moved back enough to allow the lock tab to clear the pin. Disconnect the pushrod from the pedal pin.
  18.  
  19. Under the dash at the firewall, remove the 4 bolts holding the hydraulic assembly.
  20.  
  21. Remove the hydraulic assembly from the engine compartment.
  22.  

To install:
  1. Position the hydraulic assembly and install the retaining nuts. Tighten the nuts to 21 ft. lbs. (28 Nm).
  2.  
  3. Coat the contact surface of the pedal pin with all-purpose grease. Connect the pushrod to the pedal pin and install a new retainer clip. Make certain the lock tab on the retainer is firmly engaged.
  4.  


WARNING
The hydraulic assembly pushrod must be in the correct position before assembly.

  1. Install the brake lines, then tighten them to 12 ft. lbs. (16 Nm).
  2.  
  3. If the proportioning valves were removed, reinstall, then tighten them to 30 ft. lbs. (40 Nm).
  4.  

Be certain the brake tubes are connected to the proper location.

  1. Install the return hose to the reservoir or the steel tube.
  2.  
  3. Before connecting the pressure hose to the hydraulic assembly, make certain the washers are in their correct positions. Install the hose, then tighten the banjo bolt to 13. ft. lbs. (17 Nm).
  4.  
  5. Fill the reservoir to the top of the strainer screen.
  6.  
  7. Engage all the electrical connectors to the hydraulic assembly.
  8.  
  9. Bleed the entire brake system.
  10.  
  11. Install the air cleaner and washer bottle (Van/wagon) and the fresh air intake duct and clamps.
  12.  

 
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