Installation
PROCEDUREHydraulic Control Unit Mounting Bracket:
1. Install the Hydraulic Control Unit (HCU) and mounting bracket as an assembly, on left front frame rail of the vehicle, aligning tabs on mounting bracket with holes in frame rail.
2. Install and loosely tighten the bolt attaching the HCU mounting bracket to the top of the frame rail.
3. Raise vehicle.
4. Install the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail. Then torque both mounting bolts to 28 Nm (200 inch lbs.).
5. Lower vehicle.
6. Torque bolt attaching HCU mounting bracket to top of frame rail to 20 Nm (180 inch lbs.).
Proportioning Valve Location On Hydraulic Control Unit:
7. Install the 4 chassis brake tubes onto the proportioning valves and outlet ports of the HCU. Torque the 4 chassis brake tube nuts to 17 Nm (145 inch lbs.).
Primary And Secondary Brake Tubes From Master Cylinder To HCU:
8. Install primary and secondary brake tubes from the master cylinder onto the HCU, with tube nuts only hand tightened.
Electrical Connections To HCU And Relay Box:
9. Install vehicle wiring harness connectors onto the 10 way, and 6 way connectors, located on the relay box of the HCU.
Removing Seal From Vacuum Booster:
10. 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 pry 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.
11. Remove old vacuum seal from master cylinder, if the vacuum seal came out of power brake vacuum booster when master cylinder was removed this step is not necessary.
CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal.
CAUTION: When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod.
Lubricating Master Cylinder Push Rod:
12. Lubricate master cylinder push rod as indicated only using Mopar Dielectric Grease-And No Substitutes.
Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS:
Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS:
13. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster.
CAUTION: If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Brakes, Master Cylinder Service and Repair for required vacuum seal removal procedure.
14. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod.
Master Cylinder Mounting To Vacuum Booster:
15. Install the 2 master cylinder to power brake unit mounting nuts and torque to 28 Nm (250 inch lbs.).
Fig 7 Type 3 Primary And Secondary Output Ports. With ABS:
16. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.).
Master Cylinder Fluid Level Sensor:
17. Install the wiring harness connector on the master cylinder reservoir brake fluid level switch.
18. Bleed the base brakes and the ABS brakes hydraulic systems. Refer to Brakes Service and Repair and Antilock Brake System Service and Repair for the required procedures.
19. Road test vehicle to ensure proper operation of the base and ABS brake systems.