Chrysler Caravan/Voyager/Town n Country 1984-1995

Hydraulic Reservoir

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REMOVAL & INSTALLATION




CAUTION
This brake system uses a hydraulic accumulator which, when fully charged, contains brake fluid at very high pressure. Before disconnecting any hydraulic lines, hoses or fittings be certain that the accumulator pressure is completely relieved. Failure to depressurize the accumulator may result in personal injury and/or vehicle damage.

  1. Depressurize the brake system.
  2.  
  3. Using a syringe or similar tool, remove as much brake fluid as possible from the reservoir.
  4.  
  5. Disconnect the high pressure hose banjo fitting and remove the hydraulic bladder accumulator from the hydraulic assembly.
  6.  
  7. Remove the 3 retaining pins holding the reservoir to the hydraulic assembly.
  8.  
  9. Use a blunt prying tool carefully installed between the reservoir and hydraulic assembly body to lift the reservoir. Use a rocking motion to gently lift the reservoir free of the grommets.
  10.  

Be extremely careful to avoid damaging or puncturing the reservoir.

  1. Remove the fluid level sensor switch from the reservoir.
  2.  
  3. Use fingers only to remove the grommets from the hydraulic assembly. Discard the grommets.
  4.  

To install:
  1. Lubricate new grommets with clean brake fluid and install them onto the hydraulic assembly. Always use new grommets.
  2.  
  3. Install the fluid level switch into the reservoir. Position the reservoir on the grommets and press it into place using hand pressure only. A rocking motion is helpful; make certain the reservoir is fully seated in all 3 grommets.
  4.  

Do not attempt to pound the reservoir into place with a hammer or other tools. Damage will result.

  1. Install the 3 locking pins to hold the reservoir in place.
  2.  
  3. Reinstall the high pressure hose banjo fitting onto the hydraulic assembly, then tighten the fitting to 10 ft. lbs. (14 Nm).
  4.  
  5. Install the hydraulic bladder accumulator onto the hydraulic assembly, then tighten the fitting to 30 ft. lbs. (40 Nm).
  6.  
  7. Fill the reservoir to the top of the strainer screen with fresh clean fluid.
  8.  
  9. Bleed the entire brake system including the booster.
  10.  

 
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