Removal and Installation

NOTE: Before proceeding, review SERVICE WARNINGS AND CAUTIONS at Brakes and Traction Control, Service Precautions.

REMOVAL






1. Remove the remote ground cable from the ground 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 such as shown 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. See Hoisting in Maintenance.






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.






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






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.






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






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






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






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






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 CAB connector while disconnected from the CAB.






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.






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 Disassembly and Assembly to separated the CAB from the HCU.

INSTALLATION
1. Install the ICU back in the vehicle and on its mounting bracket using the reverse order of its removal.
2. Install isolators, washers and attaching bolts, mounting the ICU to its mounting bracket.
3. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.).

CAUTION: Before installing the 25-way connector in the CAB be sure that the seal is properly installed in the connector.

4. Install the 25-way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 25-way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the 25-way connector into the socket on the CAB and lock it in the installed position.
5. Install the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.
6. Install the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.
7. Tighten the 3 bolts mounting the HCU mounting to the front suspension crossmember to a torque of 28 Nm (250 inch lbs.).
8. Install the primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports.
9. Install the 4 chassis brake tubes in the outlet ports on the HCU.










10. Using a crow foot tighten all of the brake tube nuts to a torque of 17 Nm (145 inch lbs.).
11. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten the attaching bolt.
12. Install exhaust system in vehicle using the reverse steps of its removal.
13. Install right side engine compartment splash shield back on the vehicle.
14. Lower vehicle.
15. Remove brake pedal holding tool.
16. Install the remote ground cable onto the ground stud located on left shock tower. Install the remote ground cable attaching nut and tighten to a torque of 28 Nm (250 inch lbs.).
17. Bleed the base brakes and the ABS brakes hydraulic system. Refer to Brakes, Brake Bleeding for the proper bleeding procedure.
18. Road test vehicle to ensure proper operation of the base and ABS systems.