ANTI-LOCK BRAKE SYSTEM

General Information

The Teves Mark IV-g Anti-lock Brake System (ABS) was an option on the
1996 Chrysler Minivan models. Beginning in 1997, these same models are
equipped with the Teves Mark 20 ABS system. Both of these ABS systems
operate in basically the same manner, however, they may use some different
components.

When conventional brakes are applied in an emergency stop or on ice, one or

more wheels may lock. This may result in loss of steering control and vehicle
stability. The purpose of the Anti-lock Brake System (ABS) is to prevent lock
up under heavy braking conditions. This system offers the driver increased
safety and control during braking. Anti-lock braking operates only at speeds
above 3 mph (5 km/h).

Under normal braking conditions, the ABS functions the same as a standard
brake system with a diagonally split master cylinder and conventional
vacuum assist.

If wheel locking tendency is detected during application, the system will enter
anti-lock mode. During anti-lock mode, hydraulic pressure in the four wheel
circuits is modulated to prevent any wheel from locking. Each wheel circuit is
designed with a set of electrical valves and hydraulic line to provide
modulation, although for vehicle stability, both rear wheel valves receive the
same electrical signal. The system can build or reduce pressure at each
wheel, depending on signals generated by the Wheel Speed Sensors (WSS) at
each wheel and received at the Controller Anti-lock Brake (CAB).

PRECAUTIONS

Failure to observe the following precautions may result in system damage:

• Before performing electric arc welding on the vehicle, disconnect the

control module and the hydraulic unit connectors.

• When performing painting work on the vehicle, do not expose the

control module to temperatures in excess of 185°F (85°C) for longer than 2
hours. The system may be exposed to temperatures up to 200°F (95°C) for
less than 15 minutes.

• Never disconnect or connect the control module or hydraulic

modulator connectors with the ignition switch ON.

• Never disassemble any component of the Anti-Lock Brake System

(ABS) which is designated unserviceable; the component must be replaced as
an assembly.

• When filling the master cylinder, always use brake fluid which meets
DOT-3 specifications; petroleum-based fluid will destroy the rubber parts.
 • Working on ABS system requires extreme amount of mechanical
ability, training and special tools. If you are not familiar have your vehicle
repaired by a certified mechanic or refer to a more advanced publication on
this subject.

Diagnosis and Testing

For the proper diagnostic procedure for either the entire ABS system or a
single component of the system, a scan tool (DRB or equivalent) is
necessary. Because of the complexity of the ABS system and the importance
of correct system functioning, it is a good idea to have a qualified automotive
mechanic test the system if any problems have been detected.

The self-diagnostic ABS start up cycle begins when the ignition switch is
turned to the ONposition. An electrical check is completed on the ABS
components, such as the wheel speed sensor continuity and other relay
continuity. During this check the amber anti-lock light is turned on for
approximately 1-2 seconds.

Further functional testing is accomplished once the vehicle is set in motion.

• The solenoid valves and the pump/motor are activated briefly to verify
function

• The voltage output from the wheel speed sensors is verified to be

within the correct operating range

If the vehicle is not set in motion within 3 minutes from the time the ignition
switch is set in the ONposition, the solenoid test is bypassed, but the
pump/motor is activated briefly to verify that it is operating correctly.

For the Teves Mark IV-g system fault codes are kept in a non-volatile
memory until either erased by the DRB or erased automatically after 50
ignition cycles (key ON-OFFcycles). The only fault that will not be erased
after the 50 ignition cycles is the CAB fault. On the Teves Mark 20 system,
DTCs are kept in the controller's memory until erased with the DRB scan tool,
or they are erased automatically after 3,500 miles or 255 key cycles which
ever occurs first. A CAB fault can only be erased by the DRB scan tool. More
than one fault can be stored at a time. The number of key cycles since the
most recent fault was stored is also displayed. Most functions of the CAB and
ABS system can be accessed by the DRB scan tool for testing and diagnostic
purposes.

To read the Diagnostic Trouble Codes (DTC's) perform the following:

1. Inspect the ABS components and connectors for damage and/or

proper connections. Keep in mind that the brake light circuit also provides an
input to to the ABS system. If the brake lights do not work, they must be fixed
before proceeding.

2. Connect a DRB or equivalent scan tool to the Data Link Connector

(located under the driver's side instrument panel). A scan tool must be used to
access these codes.

3. Turn the ignition to the ONposition. Wtih the scan tool, select "ABS".

4. Use the scan tool to select "Inputs/Outputs", and read the brake
switch status. While pressing on the brake pedal, check the scan tool display.
 Select "Read DTC" and record any trouble codes which may appear.
Sometimes, the cause of one trouble code may trigger additional codes to be
set. If more than one code appear, a certain sequence of tests may be
necessary. The beginning of each test will indicate if another test should be
performed first.

5. Once the problem is corrected, use the scan tool to erase the trouble
code(s).

Trouble Code Displays

The following is a list of the Teves Mark IVg Anti-lock Brake System (ABS)
trouble codes that the DRB (or equivalent) scan tool may display for 1996
Chrysler minivan models:

• Diagnostic compare

• Left front inlet valve

• Left front outlet valve

• Left front sensor circuit failure

• Left front sensor continuity < 25 MPH

• Left front sensor continuity > 25 MPH

• Left front sensor signal missing

• Left front sensor speed comparison

• Left rear inlet valve

• Left rear outlet valve

• Left rear sensor circuit failure

• Left rear sensor continuity < 25 MPH

• Left rear sensor continuity > 25 MPH

• Left rear sensor signal missing

• Left rear sensor speed comparison

• Pump motor circuit not working properly

• Pump motor not running

• Right front inlet valve

• Right front outlet valve

• Right front sensor circuit failure

• Right front sensor continuity < 25 MPH

• Right front sensor continuity > 25 MPH

• Right front sensor signal missing

• Right front sensor speed comparison

• Right rear inlet valve

• Right rear outlet valve

• Right rear sensor circuit failure

 • Right rear sensor continuity < 25 MPH

• Right rear sensor continuity > 25 MPH

• Right rear sensor signal missing

• Right rear sensor speed comparison

• System overvoltage

• System undervoltage

• Valve block feed failure

• Valve power feed circuit

The following is a list of the Teves Mark-20 Anti-lock Brake System (ABS)
trouble codes that the DRB (or equivalent) scan tool may display for 1997-99
Chrysler minivan models:

• CAB power feed circuit

• CCD communication

• Controller failure

• Left front sensor circuit failure

• Left front sensor signal failure

• Left rear sensor circuit failure

• Left rear sensor signal failure

• Pump motor circuit not working properly

• Right front sensor circuit failure

• Right front sensor signal failure

• Right rear sensor circuit failure

• Right rear sensor signal failure

• System overvoltage

• System undervoltage

Wheel Speed Sensors

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

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

... then pull the grommet down ...

 ... and unplug the connector

Next, remove the bolt that secures the wheel sensor ...
 ... and carefully remove it from the steering knuckle

The wheel sensor assembly can now be removed from the vehicle

1. Disconnect negative battery cable.

2. Carefully raise and safely support the vehicle. Remove the front wheel.

3. Remove the 2 mounting screws that attach the front channel bracket
and grommet retainer to the outer vehicle frame rail.

4. 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.

5. Remove the bolt that mounts the speed sensor head to the steering
knuckle.

6. Gently remove the speed sensor head from the steering knuckle.
 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.
7. Remove the speed sensor cable grommets from the retaining bracket.

8. Remove the wheel speed sensor from the vehicle.

To install:

9. Install the speed sensor head into the steering knuckle. Install the
mounting screw and torque to 105 inch lbs. (12 Nm).

10. 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).

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.

11. 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.

12. Install the 2 mounting bolts that attach the channel bracket to the
vehicle frame. Torque the 2 bolts to 95 inch lbs. (11 Nm).

13. 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.

14. 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.

15. Insert the sensor cable and cable grommet into the hole in the strut
tower.

16. 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).

17. Lower the vehicle. Reconnect the negative battery cable.

18. Road test the vehicle to check the operation of the ABS and base
brake systems.

Rear Wheel Sensor

Rear wheel speed sensor location (vehicles with drum brakes)

Rear wheel speed sensor location (vehicles with disc brakes)

The rear wheel speed sensor cable routing detail

Remove the grommet in the floor pan to access the speed sensor cable connector

1. Disconnect the negative battery cable.

2. Carefully raise and safely support the vehicle. Remove the rear wheel.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. Remove the speed sensor head mounting bolt from the rear bearing.
Remove the wheel speed sensor head from the rear bearing assembly.

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.
9. Remove the wheel speed sensor from the vehicle.

To install:

10. 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).

11. 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).

12. 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.

13. Install the speed sensor cable into the rear brake flex hose routing
clips.

14. If installing the right rear speed sensor cable, install the cable
grommet onto the rear axle brake flex hose bracket.

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.
15. 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.

16. 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).

17. Lower the vehicle to the ground.

18. Reconnect the negative battery cable. Road test the vehicle and check
for proper base and ABS braking system operation.

TESTING

1. Inspect the sensor and its connector. If the sensor looks damaged or
connector looks disengaged, repair it as necessary.

2. With the ignition key turned OFF, disengage the wheel speed sensor
connector. Inspect the condition of the terminals and repair as necessary.

3. Using an ohmmeter, measure the resistance between the wheel speed

sensor connector terminals on the sensor side.

4. The resistance should measure 900-1300 ohms. If the resistance

measures outside this value, replace the wheel speed sensor.

5. Then, measure the resistance between either one of the wheel speed
sensor pins and ground on the sensor side.

6. If the resistance measures below 15k ohms, replace the wheel speed
sensor.

Controller Anti-lock Brakes (CAB)

REMOVAL & INSTALLATION

 1996 Vehicles

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

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. Disconnect the negative battery cable.

3. Loosen the retaining bolt, then unplug the 60-pin wiring harness
connector from the CAB.

4. Remove the 2 nuts attaching the CAB mounting bracket to the brake
pedal bracket, then remove the CAB from the vehicle.

To install:
 5. 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).

6. 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.

7. Tighten the 60-way connector retaining bolt and tighten to 35 inch lbs.
(4 Nm).

8. Connect the negative battery cable.

1997-99 Vehicles

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

Once the HCU is removed, the CAB can be removed

 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. 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.

3. Raise and safely support the vehicle securely on jackstands.

4. 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.

WARNING
Do not apply a 12 volt power source to any terminals of the 25-way connector
when it is disengaged.
5. To prevent possible hydraulic system contamination, thoroughly clean
the HCU and brake tubes. Use MOPAR® Brake Parts Cleaner, or an equivalent
solvent.

6. Label and disconnect the chassis brake tubes from the inlet and outlet
ports of the HCU.

7. Remove the 3 bolts attaching the HCU mounting bracket to the front
suspension crossmember.

8. Remove the HCU and the mounting bracket as a unit from the vehicle.

9. Remove the 3 bolts mounting the HCU to the mounting bracket.

Separate the HCU from the mounting bracket.

10. Unplug the pump motor wiring harness from the CAB.

11. Loosen the 4 mounting bolts, then separate the CAB from the valve
block of the HCU.

To install:
 12. 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).

13. Plug the pump motor wiring harness into the CAB.

14. Install the HCU onto the mounting bracket and tighten the 3 mounting
bolts to 97 inch lbs. (11 Nm).

15. 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).

16. 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).

17. 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. 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.

18. Install the routing clips onto the brake tubes.

19. Lower the vehicle.

20. Connect the negative battery cable.

21. Remove the brake pedal positioning tool from the vehicle.

22. Bleed the base brake system and the ABS hydraulic system.

23. Road test the vehicle to ensure proper operation of the base and ABS
systems.

Hydraulic Control Unit (HCU)

REMOVAL & INSTALLATION

1996 Vehicles
 The HCU is located on the front suspension crossmember

The Hydraulic Control Unit (HCU) is located on the driver's side of the
vehicle, mounted onto the front suspension crossmember.

1. Disconnect and isolate the negative battery cable.

2. Disengage the HCU 10-way and 2-way connectors from the retaining
bracket. Then disengage the HCU 10-way and 2-way connectors from the
vehicle wiring harness located on the driver's side strut tower.

3. Disconnect the HCU wiring pigtail retaining straps from the master
cylinder brake tubes. There are 2 retaining straps, one above and one below,
the steel braid on the master cylinder tubes.

4. Using a brake pedal positioning tool, or equivalent, depress the brake

pedal past the first 1 inch of travel and hold in this position. This will isolate
the master cylinder reservoir from the brake hydraulic system, which will
prevent the brake fluid from draining out of the reservoir.

5. Raise and safely support the vehicle securely on jackstands.

6. Using Brake Parts Cleaner, thoroughly clean all surfaces, brake line
fittings and connections to the HCU.

7. Label and disconnect the chassis brake tubes from the inlet and outlet
ports of the HCU.

8. Remove the 3 bolts attaching the HCU mounting bracket to the front
suspension crossmember.

9. Remove the HCU and the mounting bracket as a unit from the vehicle,
pulling the HCU wiring pigtail through the opened master cylinder tube clip
retaining straps.

To install:

10. Locate and lock the HCU wiring pigtail into the routing clips located on
the primary and secondary master cylinder-to-HCU brake tubes. When the
wiring pigtail is installed in the routing clips, be sure that the brake tubes and
wiring harness do not touch any other components.
 11. 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).

12. 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).

13. Lower the vehicle.

14. Engage the HCU 10-way and 2-way connectors into the vehicle wiring
harness connectors.

15. Install the HCU 10-way and 2-way connectors back into the bracket
located on the driver's side strut tower.

16. Connect the negative battery cable.

17. Remove the brake pedal positioning tool from the vehicle.

18. Bleed the base brake system and the ABS hydraulic system.

19. Road test the vehicle to ensure proper operation of the base and ABS
systems.

1997-99 Vehicles

Refer to the removal and installation procedures outlined under

Controller Anti-lock Brakes (CAB), earlier in this section.

Proportioning Valve

REMOVAL & INSTALLATION

Proportioning valve detail for ABS-equipped vehicles

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. Raise and safely support the vehicle securely on jackstands.

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

3. Remove the 4 brake lines from the inlet and outlet ports of the
proportioning valve.

4. Remove the bolts securing the proportioning valve bracket to the

vehicle frame rail. Remove the proportioning valve assembly from the vehicle.

To install:

5. Place the proportioning valve assembly into position on the frame rail.
Install the mounting bolts and tighten to 10 ft. lbs. (14 Nm).

6. Install the chassis brake lines into the proportioning valve assembly.
Tighten the brake line fittings to 12 ft. lbs. (16 Nm).

7. Bleed the brake system.

8. Lower the vehicle.

9. Carefully road test the vehicle to verify proper brake system operation.

Tone (Exciter) Ring

REMOVAL & INSTALLATION

Rear Wheel (All Wheel Drive Only) and Front Wheel Tone Rings

The front ABS tone ring and rear ABS tone ring (All Wheel Drive only) are
integral components of the halfshaft assemblies and therefore, cannot be
serviced separately. If any of these tone rings require service, the halfshaft
assembly must be replaced.

However, the rear ABS tone ring on front wheel drive vehicles can be serviced
separately.

Rear Wheel (Front Wheel Drive Only)

 The rear tone wheel on front wheel drive vehicles must be removed with a special puller

Installing a tone wheel onto a new hub/bearing with an arbor press

1. Remove the rear wheel speed sensor from the rear hub/bearing flange.

2. Remove the rear wheel hub/bearing assembly from the vehicle.

3. Install 3 lug nuts on 3 of the wheel mounting studs to prevent possible

thread damage while installing the assembly in a bench vise. Using Puller
Special Tool C-4693, or equivalent, remove the tone wheel from the back of
the hub/bearing assembly.

To install:

4. Position the hub/bearing assembly in an arbor press supported by

Receiver Special Tool 6062A-3. Position Driver Special Tool 6908-1 with the
undercut side facing up on top of the tone wheel.

5. Press the tone wheel onto the hub/bearing assembly until it fits flush
with the end of the hub shaft.

6. Install the hub/bearing assembly onto the vehicle.

7. Install the rear wheel speed sensor onto the rear hub/bearing flange.

8. 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).

9. Install the brake drum/rotor.

10. Install rear wheel(s).

11. Adjust the rear brakes.

Bleeding the ABS System

The bleeding procedure is a 2-step process, one of which will require use of
the DRB scan tool or its equivalent. Bleed the system as follows:

1. Locate the diagnostic connector under the dash panel to the left of the
steering column cover.
 2. Connect the DRB scan tool to the connector. Install the correct
cartridge for the Anti-Lock Brake systems. Check to make sure the CAB
(Controller Anti-lock Brakes) does not have any fault codes stored in it. If it
does, remove them using the DRB scan tool.

CAUTION
Be sure to always wear safety glasses when bleeding the brake system. This will
prevent personal injury to your eyes in case fluid squirts out at high pressure.
3. Bleed the base brake system using the non-ABS manual bleeding
method as outlined earlier in this section. Be sure to bleed the brake system
in the correct sequence.

4. Utilizing the scan tool, go to the "Bleed ABS" routine. Firmly apply the
brake pedal to initiate the "Bleed ABS" cycle one time. Release the brake
pedal.

5. Using the scan tool, go on to bleed the Anti-Lock Brake System

according to the scan tool literature.

6. Once bleeding with the scan tool is complete, repeat the conventional
bleed procedure for the base brake system.

7. Perform this procedure until the brake fluid flows clear and free of air
bubbles. Check brake fluid level periodically to prevent the reservoir from
running low on fluid. Top off the master cylinder reservoir to the proper level
with DOT 3 type brake fluid only.

8. Road test the vehicle to check for proper brake system operation.

Brake Specifications and Troubleshooting

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Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.