Master Cylinder Removal and Installation

REMOVAL

Master Cylinder Fluid Level Sensor:

1. Remove vehicle wiring harness connector from brake fluid level sensor, in master cylinder brake fluid reservoir.

Master Cylinder Primary And Secondary Ports With ABS:

Primary And Secondary Ports Without ABS:

2. Disconnect the primary and secondary brake tubes from master cylinder outlet ports. Install plugs at all open brake tube outlets on master cylinder assembly.
3. Using Mopar, Brake Parts Cleaner or an equivalent, clean area where master cylinder attaches to booster.

Master Cylinder Mounting To Vacuum Booster:

4. Remove the 2 nuts attaching master cylinder assembly to power brake vacuum booster.
5. Slide master cylinder assembly straight off its mounting studs on power brake vacuum booster.

BLEEDING MASTER CYLINDER

Bleeding Tubes Attached To Master Cylinder Without ABS:

1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 to the master cylinder outlet ports. Position tubes so outlets of Bleeding Tubes will be below surface of brake fluid when reservoir is filled to proper level.
2. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an Equivalent.

Bleeding Master Cylinder:

3. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Continue to repeat this step several times after no more air bubbles are expelled from bleed tubes to ensure all air is bled from master cylinder.
4. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir.
5. Remove master cylinder from vise.

NOTE: Note: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled upon installation.

INSTALLATION
1. Position master cylinder assembly on studs of power brake unit, aligning push rod on power brake vacuum booster with piston of master cylinder.
2. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 28 Nm (250 inch lbs.).
3. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 inch lbs.).