Removal

NOTE: Before proceeding, review Service Precautions.

Ground Cable Attachment At Strut Tower:

1. Remove the remote ground cable from the around stud on the left strut tower.

Correctly Isolated Remote Ground Cable:

2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown and installing the nut on the stud. This will prevent accidental grounding of the remote ground cable.

Brake Pedal Holding Tool Installed:

3. Using a brake pedal positioning tool, depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.
4. Raise vehicle on jackstands or centered on a hoist.

Right Side Splash Shield:

5. Remove the splash shield from the right side of the engine compartment.
6. Remove entire exhaust system from the vehicle as a complete assembly using the following steps:
a. Disconnect the oxygen sensor wiring harnesses from the vehicle wiring harness.
b. Remove the ground strap between the frame and muffler at the muffler bracket.

Exhaust Pipe Mounting To Exhaust Manifold:

c. Remove attaching bolts from exhaust pipe at exhaust manifold on engine.

Exhaust System Support/Isolators Locations:

d. Remove all exhaust system support/isolators from the vehicle's exhaust system. Remove support/isolators from brackets on exhaust system components and leave attached to body of vehicle.
e. Lower exhaust system as a complete assembly away from the underbody of the vehicle.

HCU Heat Shield:

7. Remove the heat shield for the HCU from the HCU mounting bracket.
8. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the HCU. Also, thoroughly clean all brake tube to HCU connections.

Chassis Brake Tube Connections To HCU:

9. Remove the 4 chassis brake tubes from the outlet ports on the HCU.

Master Cylinder Brake Tube Connections To HCU:

10. Remove the primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports.

HCU Mounting Bracket Front Bolt:

11. Remove the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.

HCU Mounting Bracket Rear Bolts:

12. Remove the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.

HCU To Bracket Mounting Bolt:

13. Remove bolt attaching the side of the HCU to the mounting bracket.

HCU To Bracket Mounting Bolt:

14. Remove the 2 bolts attaching the top of the HCU to the mounting bracket.

CAUTION: Do not apply a 12-volt power source to any terminals of the 25-way HCU connector when disconnected from the CAB.

Unlocked CAB Connector:

15. Disconnect the 25 way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 25-way connector and pull it out from the connector as far as possible. This will unlock and raise the 25-way connector out of the socket on the CAB.

ICU Remove And Install:

16. Remove the ICU from its mounting bracket. Then remove the ICU from the vehicle by pulling it out through the area between the right drive shaft and frame rail.
17. Refer to the OVERHAUL procedure to separated the CAB from the HCU.