Clutch Master Cylinder - Installation

INSTALLATION

CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.





1. Install clutch master cylinder body (4) to the clutch pedal bracket assembly and 1/4 turn counter clockwise to secure.
2. Insert hydraulic tube (6) into master cylinder pressure-line connector (5) and install retaining clip.
3. Connect clutch master cylinder rod (3) to clutch pedal pin. An audible "click" should be heard.






NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.






4. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position.
5. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step.






CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.

6. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).





7. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1).
8. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.

9. Install and adjust the stop lamp switch in the brake pedal bracket Stop Lamp Switch - Installation.





10. Install the steering column cover reinforcement (1) (if equipped) using the four mounting screws (2).





11. Install the steering column opening cover on the instrument panel.






CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces.

12. Connect the vacuum hose (2) to the vacuum check valve (1).





13. Install the relay bracket (2) to the fuel filter (3) using mounting bolt (1) (if equipped).

14. Install the tube bundle routing clip (with tubes) onto the stud on the left side of the dash panel.




15. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 Nm (150 in. lbs.).

16. Install the left front brake tube into the clip located on the left body rail.
17. Install the master cylinder Brake Master Cylinder - Installation.
18. Verify that brake master cylinder reservoir (1) is full. Top off with DOT 3 brake fluid if necessary.




19. Reposition the PCM and bracket (4) into mounting position (if equipped).
20. Install bolt (2) for the PCM mounting bracket to lower shock tower and tighten to 9 Nm (80 in. lbs.) (if equipped).
21. Install nut (1) for the PCM mounting bracket to upper shock tower stud and tighten to 9 Nm (80 in. lbs.) (if equipped).

22. Connect battery negative cable Battery Cables - Installation.
23. Bleed the base brake system Service and Repair.
24. Bleed clutch system Service and Repair.
25. Actuate clutch pedal a minimum of fifteen times to allow any air ingested into the system to vent to the master cylinder reservoir.




26. Install the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine.

27. Road test the vehicle to ensure proper operation of the clutch and brakes.