Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Master Cylinder

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Overhaul



To disassemble the master cylinder remove or detach the following:



Damper and pushrod. They are held in by friction of the rubber boot.
 
Piston retention snap ring.
 
Piston assembly
 


WARNING
Do not disassemble the piston



Roll pin
 
Reservoir nipple and seal
 
Damper and seal (3.0L engine)
 

To inspect the master cylinder and its parts:



Check the inside cylinder body for rust and scars.
 
Check the piston cup for wear and deformation.
 
Check the piston for rust and scars.
 
Check the pipe connection for clogging.
 

To assemble:


NOTE
The wear item on the master cylinder is the piston assembly, spring and rubber boot. These are available from DaimlerChrysler as a repair kit.

Assemble in the following order:



Damper and seal (3.0L engine)
 
Reservoir nipple and seal
 
Roll pin
 

  1. Lubricate piston assembly with clutch fluid and insert into the master cylinder
  2.  
  3. Compress the piston with a suitable tool and install the retention snap ring.
  4.  
  5. Lubricate the rubber boot with rubber-compatible grease and install on the master cylinder.
  6.  
  7. Adjust the clevis so that the center of its hole is 4.69 inches (119.25mm) from the master cylinder flange.
  8.  

Removal & Installation



  1. Drain the clutch fluid
  2.  
  3. Remove clutch master cylinder cap
  4.  
  5. Attach a hose to the slave cylinder bleed screw and insert the hose into a clean container
  6.  
  7. Loosen the bleed screw
  8.  
  9. Remove or disconnect the following:

    Clevis pin
     
    Clutch tube connection
     
    Reservoir hose connection
     
    Clutch master cylinder from firewall
     

  10.  
  11. The fluid reservoir will need to be moved over to a new or rebuilt clutch master cylinder during replacement.
  12.  

To install:

  1. When installing the master cylinder it should be bled before the clutch tube is reconnected.
  2.  
  3. Install the master cylinder and torque the nuts to 22 inch lbs. (13 Nm).
  4.  
  5. Attach the reservoir bracket, tank and hose.
  6.  
  7. Attach a bench bleeding hose to the master cylinder's port, fill the reservoir with fluid and pump and release the clutch pedal until no more air bubbles are seen in the reservoir.
  8.  
  9. Install the clutch tube and bleed the slave cylinder.
  10.  

 
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