B. ABS High Pressure Hose Replacement -- BB-Body

1. Pump the brake system pressure down by turning the ignition off and applying the brake pedal approximately 45-50 times, until the pedal becomes firm.

2. With the ignition still off, disconnect the battery ground.

3. Remove the fresh air intake duct from the vehicle.

4. Clean the connecting points for the high pressure hose (Figure 7). Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.





5. Disconnect the high pressure hose from the hydraulic assembly (Figure 7).

6. Cut the 3 tie straps attaching the high pressure hose, low pressure hose and wiring harness together (Figure 7).





7. Remove the bolt from the brake hose attaching clip and undo the spring clip with channel lock pliers (Figure 8).

8. Remove the high pressure hose from the clip and pull the hose clear of any obstructions so it can be pulled out from under the vehicle.

9. Raise the vehicle on a hoist.

10. Disconnect the pump end of the high pressure hose from the pump and motor assembly by removing and saving the banjo bolt.

Caution:
do not disturb the pump end of the low pressure hose. After removing the connector block, the low pressure hose is only retained by the internal O-ring seal.

11. Remove the high pressure hose from the vehicle.

12. Clean the pump contact face for the high pressure hose. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.

13. Lubricate the supplied O-Rings with brake fluid and install the large O-Ring on the connector block face of the supplied high pressure hose, and the small Oring on the cleaned banjo bolt.

14. Route the high pressure hose along the low pressure hose up into the engine compartment.

15. Install the high pressure hose connector block end to the pump face with the banjo bolt. Tighten to 10 ft.lbs (14 N-m) torque.

16. Lower the vehicle and finish routing the hose to the hydraulic assembly.

Important:
use care and do not twist the high pressure hose when routing it to the reservoir.

17. Reinstall the high and low pressure hoses in the brake hose clip, and reinstall the clip attaching bolt to the shock tower.

18. Remove the cap from the fitting on the supplied high pressure hose and install the end of the high pressure hose to the hydraulic assembly. Tighten to 145 in.lbs. (16 N-m) torque.

19. Install the 3 supplied tie straps around the hose assembly and wiring harness as shown in (Figure 7).

20. Reinstall the fresh air intake duct.

21. Reconnect the battery ground.

22. Turn the ignition switch to the ON position to start the brake booster pump. Apply the brake pedal several times to distribute the fluid.

23. Check the master cylinder reservoir fluid level by performing the following procedure:

^ Turn the ignition off and pump the brake pedal 40 to 50 times, until the pedal is hard. The fluid level should be at the top of the inlet screen. Add brake fluid as necessary using new Mopar brake fluid or an equivalent with SAE 1703 and DOT 3 ratings.

^ Start the vehicle and evaluate the brakes for proper function.