Removal

CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done simply by pumping the brake pedal until a firm pedal is achieved, with the ignition off.

1. On ABS equipped vehicles, with engine not running, pump the brake pedal until a firm pedal is achieved (4 - 5 strokes).

Master Cylinder Fluid Level Sensor:

2. Remove vehicle wiring harness connector from brake fluid level sensor located in master cylinder brake fluid reservoir.

Primary And Secondary Brake Tubes W/O ABS Brakes:

Primary And Secondary Brake Tubes With ABS Brakes:

3. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs at all open brake tube outlets on master cylinder assembly.
4. On vehicles equipped with ABS, clean area where master cylinder attaches to booster using a suitable brake cleaner such as Mopar Brake Parts Cleaner or an equivalent.

Master Cylinder Mounting To Vacuum Booster:

5. Remove the 2 nuts attaching master cylinder housing to power brake vacuum booster.
6. Slide master cylinder assembly straight out of the power brake vacuum booster.

Vacuum Seal Removal From Power Brake Booster:

CAUTION: On vehicles equipped with ABS, the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal in the front of the power brake vacuum booster MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster.

7. If vehicle is equipped with ABS, remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and prying seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster.

Power Brake Vacuum Booster Check Valve:

8. Disconnect vacuum hoses from check valve on power brake vacuum booster. Do not remove check valve from power brake vacuum booster.

NOTE: If vehicle is equipped with antilock brakes, the Hydraulic Control Unit (HCU) needs to be removed from the vehicle to allow removal of the power brake vacuum booster.

Input Rod Retaining Pin:

9. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver under the center

CAUTION: Discard retaining clip when removed, it is not to be reused. Replace only with a new retaining clip when assembled.

10. Rotate screwdriver enough to allow retaining clip tang to pass over the end of the brake pedal pin.

Power Brake Booster Mounting:

11. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. The nuts are accessible from under the instrument panel in the area of the steering column and brake pedal bracket.
12. Slide power brake vacuum booster forward until mounting studs clear dash panel, then tilt the booster up and to the center of the vehicle to remove.