I recently purchased a 97 T&C from the original owner. The brakes are spongy and the emergency brake won't hold the van on a hill. The original owner said the brakes had "always been that way" and said he had just had a brake job by his local Chrysler dealer. The brake fluid level is correct and no emergency lights show.

One mechanic suggested another braker job with better pads. That's one possibility.

Anyone else had this problem and figured it out?

The mechanic who gave that advise to replace the pads is just looking for new business. Unless the pads are squealing, they should be ok. Also, I would be suspisous that any brake job done included the rear wheels.

Your problem is that the automatic adjuster system in one of the rear wheels is not working. You will probably notice if you hit the brake pedal once that the point where the brake engage is very low to the floor. This is known as a low brake pedal.

The rear brakes consists of brake shoes and drum. They have actuator and an expanding star adjustor for keeping the shoes very close to the drum. As the shoes wear, the actuator turns the star adjuster which spreads the shoes wider. If this system is not working, it requires longer and longer pedal movement to move the shoe to the drum, and since only the top of the shoe engages, there is less braking force applied.

It only takes one non-functioning wheel adjuster to cause this. Usually, either the star adjustor has rusted up threads or a small cable that actuates the adjustment is rusted thru.

This is very likely the problem with the emergency brake not holding.

He is right . Just did this today! Same problem, right remedy!

Definitely agree with previous diagnosis, especially if the park brake doesn't hold. If you don't mind jacking the vehicle up, you can tweak the self-adjuster yourself and buy some time before the next brake job. Lift one rear wheel with a jack (and put an axle stand under to be safe :), pop the little black rubber plug out of the slot on the bottom of the backing plate and with a flashlight locate the star wheel on the barrel of the self-adjuster which should be visible thru the slot. To adjust it, insert a flat screwdriver and ratchet the star wheel DOWNWARD to move the bottom of the shoes out towards the brake drum to improve braking. As you click the star wheel down, spin the tire until the shoes start rub and back off a few clicks. This can be a bit of trial and error, just make sure you don't leave them rubbing constantly. Repeat with the other rear wheel. The one that takes the most clicks before it starts to rub is the one that is not self-adjusting. If they both only take a couple of clicks, look somewhere else for the problem. If the star wheels are so rusted they are stuck, you have to do a rear brake job. If the star wheel rotates without clicking, the self-adjuster is out of place (see previous post about the small cable rusting thru). The "click" comes from the adjuster bumping over the teeth on the star wheel. Always a good idea to do a little road test on a quiet street to be sure the brakes aren't over adjusted.

I had spongy brakes, even after 3 new master cylinders, a power booster, and two new front calipers on my 97 Voyager. We finally replaced the ABS controler ($100 used + $165 dealer installation) and the pedal is now hard. Before this was done, we couldn't get a good bleed, especially on the left front. Good Luck.

I had spongy brakes, even after 3 new master cylinders, a power booster, and two new front calipers on my 97 Voyager. We finally replaced the ABS controler ($100 used + $165 dealer installation) and the pedal is now hard. Before this was done, we couldn't get a good bleed, especially on the left front. Good Luck.
hi i have the same problem spongy brakes and the pedal wont go hard.and the brakes are shite.i have changed all the brake pads and shoes .master cylinder and bled the brakes from air and i still have the problem.any ideas please help

hi i have the same problem spongy brakes and the pedal wont go hard.and the brakes are shite.i have changed all the brake pads and shoes .master cylinder and bled the brakes from air and i still have the problem.any ideas please help


I replaced the ABS controler with a used unit last month and the problem is solved. Remember, I couldn't even bleed the left front brake so if you get a good bleed this may not be your problem.

I replaced the ABS controler with a used unit last month and the problem is solved. Remember, I couldn't even bleed the left front brake so if you get a good bleed this may not be your problem.
hi again i think i have the same problem as your self.could you tell me were the abs controller is and is it a big item.also you wouldent have a part number for one would u as the dealers need a part number.thanx

I replaced the ABS controler with a used unit last month and the problem is solved. Remember, I couldn't even bleed the left front brake so if you get a good bleed this may not be your problem.where is the abs controler on the veihcal as i am from the (uk) and cannot get hold of a manual, i am doing all the work my self ,there also is a release of air from the small unit at the side of the fuse box in the engine bay,ther are 2 small pipes coming of it and thay run to the servo ,and the vacume thingy above the turbo, is this the abs controler ,or can you send a picture , just a bit of information to all who have a voyager ,i got my master cilinder seal cut by laser at a cost of £45.00 an had it presher tesed and it was exerlant ,so no need to buy a new one as you can recondition your old one