Chrysler Caravan/Voyager/Town and Country 1996-1999

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: The master cylinder uses a special filler tube to allow easier filling of the reservoir

It is very important to understand that different types of master cylinders are used on this vehicle. Vehicles equipped with traction control utilize a center port master cylinder, while vehicles not equipped with traction control utilize a compensating port master cylinder. Be sure to verify if the vehicle being worked on is equipped with traction control or not equipped with traction control and that the correct master cylinder is installed. Also, vehicles equipped with four wheel disc brakes use a master cylinder with a different piston bore than the other master cylinders. Be sure to install the correct master cylinder for the type of brake system that the vehicle is equipped with.

  1. With the engine turned OFF, pump the brake pedal several times until a firm brake pedal is achieved.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. To prevent possible hydraulic system contamination, thoroughly clean all surfaces of the brake fluid reservoir, filler neck and master cylinder. Use MOPAR® Brake Parts Cleaner, or an equivalent solvent.
  6.  



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Fig. Fig. 2: Before removing the master cylinder from the booster, disconnect the brake tubes



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Fig. Fig. 3: The vacuum seal must be replaced each time the master cylinder is removed

  1. Remove the brake fluid reservoir filler tube by pushing down and turning. Remove the cap from the removed filler tube and install it on the brake fluid reservoir.
  2.  
  3. Disconnect the brake fluid level sensor wiring connector from the side of the brake fluid reservoir.
  4.  
  5. Disconnect the brake lines from the master cylinder. Plug the outlet ports and brake lines to prevent fluid loss and dirt entry.
  6.  
  7. To prevent any dirt particles from falling into the vacuum booster, thoroughly clean the master cylinder and power brake booster using MOPAR® Brake Parts Cleaner, or equivalent. Remove the master cylinder attaching nuts and remove the master cylinder.
  8.  
  9. Remove the vacuum seal located on the mounting flange of the master cylinder by carefully pulling it away from the master cylinder. Discard the old vacuum seal.
  10.  

To install:
  1. Bench bleed the replacement master cylinder.
  2.  
  3. Install a new vacuum seal onto the master cylinder. Be sure the new seal is seated squarely in the groove of the master cylinder casting.
  4.  
  5. Position the master cylinder on the booster studs, aligning the booster pushrod with the master cylinder piston. Secure the master cylinder with the mounting nuts. Torque the mounting nuts to 18 ft. lbs. (25 Nm).
  6.  

  1. Reconnect the primary and secondary brake lines to the primary and secondary ports in the master cylinder. Make sure the fluid in the reservoir is at the proper level.
  2.  
  3. Have an assistant apply the brake pedal. With the pedal depressed, loosen the forward brake line fitting until the brake pedal drops to the floor. Tighten the fitting before the brake pedal is allowed to return. Repeat until no more air bubbles are released.
  4.  
  5. Repeat the previous Step at the rear brake line.
  6.  
  7. Final tighten the brake lines at the master cylinder, being sure to hold the brake lines securely during the tightening of the brake line fittings to control orientation of the flex section. Torque the brake line fittings to 13 ft. lbs. (17 Nm).
  8.  

  1. Reconnect the wiring connector to the brake fluid level sensor on the side of the master cylinder.
  2.  
  3. Install the filler tube onto the master cylinder brake fluid reservoir.
  4.  
  5. Reconnect the negative battery cable. Refill the master cylinder brake fluid reservoir and bleed the brake system.
  6.  
  7. Road test the vehicle using extreme caution while testing brake system operation. Check the brake fluid level and top off if necessary.
  8.  

BENCH BLEEDING



See Figures 4 and 5



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Fig. Fig. 4: Mounting the master cylinder in a vise for bleeding



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Fig. Fig. 5: Bleeding tubes installed on a master cylinder for bleeding


WARNING
All new master cylinders should be bench bled prior to installation. Bleeding a new master cylinder on the vehicle is not a good idea. With air trapped inside, the master cylinder piston may bottom in the bore and possibly cause internal damage.

  1. Secure the master cylinder in a bench vise using only the master cylinder mounting flange.
  2.  
  3. Remove the master cylinder reservoir cap.
  4.  
  5. Manufacture or purchase bleeding tubes and install them on the master cylinder as illustrated.
  6.  
  7. Fill the master cylinder reservoir with clean, fresh brake fluid until the level is within 0.25 in. of the reservoir top.
  8.  

Ensure the bleeding tubes are below the level of the brake fluid, otherwise air may get into the system making your bleeding efforts ineffective.

  1. Use a blunt tipped rod (a long socket extension works well) to slowly depress the master cylinder piston. Make sure the piston travels full its full stroke.
  2.  
  3. As the piston is depressed, bubbles will come out of the bleeding tubes. Continue depressing and releasing the piston until all bubbles are expelled from the master cylinder.
  4.  
  5. Refill the master cylinder with fluid.
  6.  
  7. Remove the bleeding tubes.
  8.  
  9. Install the master cylinder reservoir cap.
  10.  
  11. Install the master cylinder on the vehicle.
  12.  

 
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