Master Cylinder Replacement
REMOVE1. Remove wiring harness connector from brake fluid level sensor in master cylinder brake fluid reservoir.
Master Cylinder Primary And Secondary Ports With ABS:
Primary And Secondary Ports Without ABS:
2. Disconnect the primary and secondary brake tubes from the master cylinder outlet ports. Install plugs at all open brake tube outlets on master cylinder assembly.
3. Using Mopar, Brake Parts Cleaner or an equivalent, clean the area where the master cylinder attaches to the vacuum booster.
Master Cylinder Mounting To Vacuum Booster:
4. Remove the 2 nuts attaching the master cylinder to the vacuum booster.
CAUTION: When removing the routing clip and brake tubes from the mounting stud, do not bend or kink the chassis brake line tubes.
5. Remove the routing clip and chassis brake tubes (as an assembly) from the mounting stud for the master cylinder.
6. Slide the master cylinder straight off its mounting studs on the vacuum booster.
BLEEDING MASTER CYLINDER
Bleeding Tubes Attached To ABS Master Cylinder:
Bleeding Tubes Attached To Master Cylinder Without ABS:
1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 to the master cylinder outlet ports. Position the bleeding tubes so outlets of the tubes will be below the surface of the brake fluid when reservoir is filled to the proper level.
2. Fill brake fluid reservoir with brake fluid con forming to DOT 3 specifications such as Mopar or an equivalent.
Bleeding Master Cylinder:
3. Insert an appropriate size wooden dowel in the end of the master cylinder piston. Using the dowel, slowly depress the piston to the full extent of its travel and then allow the piston to return to its released position. Continue to repeat this step until bubbles no longer appear in the brake fluid. After no more air bubbles are expelled from the bleed tubes repeat the above procedure several more times to ensure all air is bled from master cylinder.
4. Remove the bleeding tubes from the outlet ports of the master cylinder.
5. Plug outlet ports of master cylinder and install the cap on the reservoir.
6. Remove the master cylinder from the vise.
NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled upon installation.
INSTALL
1. Position master cylinder assembly on studs of power brake unit, aligning push rod on power brake vacuum booster with piston of master cylinder.
CAUTION: When installing the routing clip and brake tubes on the mounting stud, do not bend or kink the chassis brake line tubes. Be sure the chassis brake tubes are routed correctly. The chassis brake tubes can not touch each other or other components or the body of the vehicle.
2. Install the routing clip and chassis brake tubes on the inboard mounting stud for the master cylinder.
3. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 28 Nm (250 inch lbs.).
4. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 inch lbs.).
5. Install the connector from the vehicle wiring harness on the fluid level sensor in the master cylinder fluid reservoir.