Chrysler Full-Size Trucks 1989-1996 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



Cast Iron Master Cylinder

See Figures 1 and 2

Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated with dirt or water, drain and flush the system. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.



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Fig. Fig. 1: A common cast iron master cylinder assembly

  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the bolt securing the pushrod to the pedal linkage.
  4.  
  5. Remove the master cylinder attaching nuts.
  6.  



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Fig. Fig. 2: Bench bleed the master cylinder by running fluid tubes into the reservoir and pumping with a wooden dowel

  1. Slide the master cylinder from the truck.
  2.  

To install:
  1. Position the master cylinder to the booster.
  2.  
  3. Install the and tighten the mounting nuts to 16 ft. lbs. (22 Nm).
  4.  
  5. Connect the pushrod.
  6.  
  7. Install all the brake lines.
  8.  
  9. Bleed the master cylinder and brake system.
  10.  

Aluminum Master Cylinder

See Figures 3, 4 and 5

  1. Disconnect the brake lines from the master cylinder.
  2.  



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Fig. Fig. 3: Disconnect the brake lines from the master cylinder outlet ports

  1. Remove the master cylinder mounting nuts.
  2.  



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Fig. Fig. 4: With the lines free, unbolt the master cylinder from the brake booster

  1. Slide the master cylinder out.
  2.  



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Fig. Fig. 5: Remove the disconnected master cylinder and set it in a clean location

To install:
  1. Position the master cylinder to the booster.
  2.  
  3. Install the and tighten the mounting nuts to 16 ft. lbs. (22 Nm).
  4.  
  5. Install all the brake lines.
  6.  
  7. Bleed the master cylinder and brake system.
  8.  

 
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