With ABS

REMOVAL

CAUTION: On Antilock Brake System (ABS) equipped vehicles, 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 wiring harness connector from the brake fluid level switch on the master cylinder reservoir.

Master Cylinder And Vacuum Booster:

4. Disconnect the primary and secondary chassis brake tubes from master cylinder. Install plugs in the master cylinder assembly outlet ports.
5. Clean the area where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Mopar Brake Parts Cleaner or an equivalent.

Master Cylinder Mounting:

6. Remove the 2 nuts attaching master cylinder to power brake booster unit.
7. Slide the master cylinder straight out of the vacuum booster unit.

INSTALLATION

NOTE: The master cylinder must be bled before installing it on the vehicle.

1. Bleed the master cylinder before installing it on the vehicle.

CAUTION: The vacuum seal at the front of the power brake booster must be replaced before reinstalling the master cylinder.

Removing Vacuum Seal From Booster:

2. Remove the used vacuum seal located in the front of the power brake vacuum booster. For vacuum seal removal, carefully insert a small screwdriver between the push rod of the power brake booster and the vacuum seal, then pry the seal out of the power brake vacuum booster.

CAUTION: Do not attempt to pry the seal out of the master cylinder by inserting a tool between the outer diameter of the seal and the power brake vacuum booster. Damage to the booster may result.

3. If the old vacuum seal came out of the power brake booster attached to the master cylinder when it was removed, pull the seal off the master cylinder push rod.

CAUTION:
^ When installing the master cylinder on a vehicle, use only the procedure detailed below for installing a new vacuum seal into the power brake vacuum booster. Be sure the old vacuum seal is removed from power brake vacuum booster before attempting to install a new seal.
^ When lubricating master cylinder push rod, use only Mopar Dielectric Grease. Using any other type of grease or lubricant on the push rod will not provide adequate long term lubrication of the push rod.

4. Install a new vacuum seal and the master cylinder into the power brake vacuum booster as follows:

Lubricating Master Cylinder Push Rod:

^ Lubricate the master cylinder push rod as indicated using only Mopar Dielectric Grease.

Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS:

Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS:

^ Install the vacuum seal on master cylinder push rod with the notches on vacuum seal pointing toward the master cylinder housing. Slide the vacuum seal onto master push rod until the seal is seated against the master cylinder housing.
^ Position the master cylinder on the studs of power brake vacuum booster aligning the booster push rod with the master cylinder push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster.
^ Install the 2 master cylinder mounting nuts. Tighten the mounting nuts to a torque of 28 Nm (250 inch lbs.) torque.

5. Connect the chassis brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.).
6. Install the wiring harness connector on the master cylinder reservoir fluid level switch.
7. Connect the negative (ground) cable on the battery.
8. Fill the master cylinder to the proper fill level.
9. Road test the vehicle to ensure proper operation of the base and antilock brake systems.