LHD Without ABS
MASTER CYLINDERREMOVAL - WITHOUT ABS
NOTE: Before proceeding, Refer to Service Precautions.
CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
2. Disconnect the negative (ground) cable from the battery and isolate the cable.
3. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place.
4. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir.
5. Disconnect the two brake tubes from the master cylinder, and two brake tubes from the proportioning valves . Install plugs at all of the open brake tube outlets on the master cylinder.
6. Clean the area around where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Mopar Brake Parts Cleaner or an equivalent.
7. Remove the two nuts attaching the master cylinder to the power brake booster.
8. Slide the master cylinder straight out of the power brake booster.
9. To remove the proportioning valves, unthread each from the master cylinder.
INSTALLATION - WITHOUT ABS
NOTE: The master cylinder must be bled before installing it on the vehicle.
1. If removed, install the proportioning valves in their master cylinder ports. The valves are identical, so they can be installed in either master cylinder port going to the rear brakes. Make sure the O-rings on the proportioning valves are new.
2. Bleed the master cylinder before installing it on the vehicle.
3. Inspect and wipe clean the O-ring vacuum seal on the master cylinder rear mounting flange to ensure a good vacuum seal once installation is complete. Replace as necessary.
4. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster.
5. Position the master cylinder on the studs of the power brake booster, aligning the push rod of the power brake booster with master cylinder piston push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster.
6. Install the two master cylinder mounting nuts and tighten each to a torque of 18 Nm (160 in. lbs.).
7. Connect the four brake tubes to the master cylinder and proportioning valve ports . Tighten all tube nuts to a torque of 17 Nm (145 in. lbs.).
8. Connect the brake fluid level switch wiring connector.
9. Install the battery and clamp it in place.
10. Connect the positive, then the negative (ground) cable on the battery.
11. Fill the master cylinder to the proper level.
12. Pump the brake pedal several times, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary.
CAUTION: It will be necessary to bleed the entire base hydraulic system if the brake system has been open to air for an excessive amount of time or air is present in the lines.
13. Check for leaks.
14. Road test the vehicle to ensure proper operation of the brakes.