Chrysler Full-Size Vans 1967-1988 Repair Guide

Master Cylinder

Print

REMOVAL & INSTALLATION



1967-72 Models
B100
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts.
  4.  
  5. Disconnect the pushrod from the pedal.
  6.  
  7. Slide the master cylinder out.
  8.  
  9. Installation is the reverse of removal. Tighten the mounting nuts to 10 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  10.  

B200 AND B300
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts.
  4.  
  5. Slide the master cylinder out.
  6.  
  7. Installation is the reverse of removal. Tighten the mounting nuts to 10 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  8.  

1973-74 Models
B100
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Disconnect the pushrod from the pedal.
  4.  
  5. Remove the master cylinder mounting nuts.
  6.  
  7. Slide the master cylinder out.
  8.  
  9. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  10.  

EXCEPT B100
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts.
  4.  
  5. Slide the master cylinder out.
  6.  
  7. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  8.  

1975-78 Models
B100
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Disconnect the pushrod from the pedal.
  4.  
  5. Remove the master cylinder mounting nuts.
  6.  
  7. Slide the master cylinder out.
  8.  
  9. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  10.  

EXCEPT B100
  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.  
  7. Slide the master cylinder from the van.
  8.  
  9. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  10.  

1979-82 Models With an Aluminum Master Cylinder
WITHOUT POWER BRAKES
  1. Disconnect the brake lines at the master cylinder.
  2.  
  3. Disconnect the stop lamp switch bracket and allow the switch to hang out of the way.
  4.  
  5. Pull the brake pedal backwards to disengage the pushrod from the master cylinder piston. This will require at least 50 lbs. of pull. It will also destroy the retention grommet.
  6.  
  7. Remove the master cylinder mounting nuts.
  8.  
  9. Slide the master cylinder straight away from the firewall. Remove all traces of the old grommet.
  10.  
  11. When installing the master cylinder, tighten the nuts to 16 ft. lbs. Moisten a new grommet with water, align the pushrod with the piston and, using the brake pedal, push the pushrod into the piston until it is fully seated. Install the boot.
  12.  
  13. Connect the stop lamp switch, adjust the switch, bleed the master cylinder and brake system.
  14.  

WITH POWER BRAKES
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts.
  4.  
  5. Slide the master cylinder out.
  6.  
  7. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  8.  

1979-88 Models With a Cast Iron Master Cylinder

See Figures 1, 2, 3 and 4

Click image to see an enlarged view

Fig. Fig. 1: Using a flare nut wrench, loosen the brake line attaching nuts at the master cylinder ...



Click image to see an enlarged view

Fig. Fig. 2: ... and then carefully pull them out and away from the master cylinder



Click image to see an enlarged view

Fig. Fig. 3: Loosen and remove the master cylinder retaining nuts ...



Click image to see an enlarged view

Fig. Fig. 4: ... then slide the master cylinder off of the mounting studs

  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.  
  7. Slide the master cylinder from the van.
  8.  
  9. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  10.  

1983-88 Models With an Aluminum Master Cylinder
  1. Disconnect the brake lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts.
  4.  
  5. Slide the master cylinder out.
  6.  
  7. Installation is the reverse of removal. Tighten the mounting nuts to 16 ft. lbs. Connect the pushrod. Bleed the master cylinder and brake system.
  8.  

OVERHAUL



See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Exploded view of a common master cylinder assembly-1984-88 cast iron model shown

1967-78 Chrysler Cast Iron Tandem Master Cylinder
  1. Clean the outside of the cylinder. Remove the cover and drain the fluid.
  2.  
  3. Loosen the rear piston retainer screw from inside the reservoir, then remove the snapring from the outer end of the cylinder bore. Remove the primary piston.
  4.  
  5. Remove the secondary piston. If the piston sticks in the cylinder, air pressure may be used to remove it. Always use new rubber cups.
  6.  
  7. Note the position of the rubber cups and springs and remove them from the pistons and from the bore.
  8.  
  9. Remove the tube seats, using an easy out or a screw threaded into the seat. Unless the seat is damaged, it is not absolutely necessary to remove the seats.
  10.  
  11. Remove the residual pressure valves and springs found under the seats.
  12.  
  13. Clean the inside of the master cylinder with brake fluid or denatured alcohol.
  14.  
  15. Closely inspect the inside of the master cylinder. Polish the inside of the bore with crocus cloth. If there is rust or pitting, it will be necessary to use a hone. Discard the master cylinder if the scores or pitting cannot be eliminated by honing.
  16.  
  17. Do not reuse old rubber parts and be sure to use all the new parts supplied in the rebuilding kit.
  18.  
  19. Before assembly, thoroughly lubricate all parts with clean brake fluid.
  20.  
  21. Replace the primary cup on the front end of the piston with the lip away from the piston.
  22.  
  23. Carefully slide the second seal cup over the rear of the piston and into the second land. The cup lip must face the front of the piston.
  24.  
  25. Slowly work the rear secondary cup over the piston and position it in the rear land. The lip must face to the rear.
  26.  
  27. Slide the retainer cup over the front piston stem with the beveled side facing away from the piston cup.
  28.  
  29. Replace the small end of the pressure spring into the retainer.
  30.  
  31. Position the assembly in the bore. Be sure the cups are not canted.
  32.  
  33. Slowly work the secondary cup over the back of the rear piston with the cup lip facing forward.
  34.  
  35. Positing the spring retainer in the center of the rear piston assembly. It should be over the shoulder of the front piston. Position the piston assembly in the bore. Slowly work the cup lines into the bore. Slowly work the cup lines into the bore, then seat the piston assembly.
  36.  
  37. Hold the pistons in the seated position. Insert the piston retaining screw with the gasket, and tighten it securely.
  38.  
  39. Replace the residual pressure valves and spring. Position them in the front outlet and install the tube seats.
  40.  

1967-78 Bendix Cast Iron Tandem Master Cylinder
  1. Clean the outside of the cylinder and insert a screw extractor in the tube seat and tighten firmly. Tap gently on the tool and remove the seat.
  2.  
  3. Remove the cover and the gasket and drain the brake fluid from the cylinder.
  4.  
  5. Remove the snapring from the open end of the cylinder. Slide out the washer and carefully remove the primary piston then the secondary piston assembly from the master cylinder.
  6.  
  7. Clean all parts in a suitable solvent and blow dry with compressed air. Wash the cylinder bore with clean brake fluid and check for scoring or pitting. If the cylinder bore walls have light scratches or show signs of corrosion, it can be cleaned with a crocus cloth. Cylinder walls that have deep scratches or scoring may be honed, providing the diameter of the bore is not increased more than 0.002".
  8.  


WARNING
Do not reuse any rubber parts! If you are using a brake cylinder rebuilding kit, use ALL the parts supplied with the kit!

  1. Dip all component parts in clean brake fluid and coat the inside of the bore with brake fluid.
  2.  
  3. Carefully slide the front piston assembly into the cylinder body.
  4.  
  5. Slide the rear piston into the cylinder body.
  6.  
  7. Compress the pistons and install and tighten the front piston retainer screw.
  8.  
  9. Hold the washer in position and install the snapring.
  10.  
  11. Install the residual pressure valve and spring in the outlet port and firmly install the tube seats.
  12.  
  13. Bleed the master cylinder before installation.
  14.  

1979-88 Aluminum Master Cylinder
  1. Clean the outside of the master cylinder.
  2.  
  3. Remove the reservoir caps and empty the brake fluid from the reservoir.
  4.  
  5. With the master cylinder in a vise remove the reservoir from the master cylinder housing by grasping and moving from side to side.
  6.  
  7. Remove the reservoir grommets from the master cylinder.
  8.  
  9. Remove the secondary piston retainer pin from inside the master cylinder housing using a pair of needle nose pliers.
  10.  

This pin is not used on 1983-88 cylinders.

  1. Remove the snapring from the outer end of the cylinder bore and slide the primary piston out of the cylinder bore.
  2.  
  3. Remove the secondary piston by tapping the open end of the master cylinder on the end of a bench. If the secondary piston sticks it may be necessary to use air pressure to force the piston out.
  4.  
  5. Note the position of the cup lips then remove the cups from the piston.
  6.  
  7. If the brass tube seats are not reusable, replace them using an "easy out" tool.
  8.  
  9. Wash the inside of the bore with clean brake fluid and check for scoring, pitting or scratches.
  10.  

Do not hone the master cylinder. If any of the above conditions exist, the master cylinder must be replaced.

  1. Dip all components in clean brake fluid and place on a clean shop towel or paper.
  2.  
  3. Install the check flow washer and carefully work the primary cup on the end of the secondary piston with the lip away from the piston.
  4.  
  5. Slide the retainer cup over the front end of the piston followed by the piston spring.
  6.  
  7. Carefully work the secondary piston secondary cup over the rear end of the secondary piston, with the cup lip away from the piston.
  8.  
  9. Keep well lubricated with brake fluid and install the secondary piston assembly into the bore of the master cylinder.
  10.  
  11. Carefully work the second cup over the end of the primary piston with the larger lip of the cup toward the piston.
  12.  
  13. Center the spring retainer of the primary piston on the secondary piston. Push the piston assemblies into the bore up to the primary piston cup. Carefully work the cup into the bore then push the piston in up to the secondary seal. Carefully work the primary cup into the bore, then push in on the piston until seated.
  14.  
  15. Depress the piston with a brass or wood rod and install the snapring.
  16.  
  17. Position the secondary piston retainer pin in the housing and tap or press it until it is firmly seated.
  18.  
  19. Install new tube seats, firmly.
  20.  
  21. Install the reservoir grommets in the master cylinder housing.
  22.  
  23. Lubricate the reservoir mounting area, then with a rocking motion, install the reservoir into the master cylinder housing.
  24.  
  25. Before installation, bleed the master cylinder.
  26.  

1979-88 Cast Iron Master Cylinder

See Figures 6, 7 and 8

Click image to see an enlarged view

Fig. Fig. 6: To disassemble the master cylinder, you must first remove the snapring



Click image to see an enlarged view

Fig. Fig. 7: After removing the snapring, you can withdraw the piston assembly



Click image to see an enlarged view

Fig. Fig. 8: Once the piston assembly is removed, you can clean and inspect all components for possible reuse

  1. Clean the outside of the cylinder and insert a screw extractor in the tube seat and tighten firmly. Tap gently on the tool and remove the seat.
  2.  
  3. Remove the cover and the gasket and drain the brake fluid from the cylinder.
  4.  
  5. Remove the snapring from the open end of the cylinder. Slide out the washer and carefully remove the primary piston then the secondary piston assembly from the master cylinder.
  6.  
  7. Clean all parts in a suitable solvent and blow dry with compressed air. Wash the cylinder bore with clean brake fluid and check for scoring or pitting. If the cylinder bore walls have light scratches or show signs of corrosion, it can be cleaned with a crocus cloth. Cylinder walls that have deep scratches or scoring may be honed, providing the diameter of the bore is not increased more than 0.002".
  8.  


WARNING
Do not reuse any rubber parts! If you are using a brake cylinder rebuilding kit, use ALL the parts supplied with the kit!

  1. Dip all component parts in clean brake fluid and coat the inside of the bore with brake fluid.
  2.  
  3. Carefully slide the front piston assembly into the cylinder body.
  4.  
  5. Slide the rear piston into the cylinder body.
  6.  
  7. Compress the pistons and install and tighten the front piston retainer screw.
  8.  
  9. Hold the washer in position and install the snapring.
  10.  
  11. Install the residual pressure valve and spring in the outlet port and firmly install the tube seats.
  12.  
  13. Bleed the master cylinder before installation.
  14.  

 
label.common.footer.alt.autozoneLogo