Chrysler Full-Size Vans 1989-1998 Repair Guide

Bleeding the Brake System


Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

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, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


See Figure 1

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Fig. Fig. 1: Bench bleeding the master cylinder using bleeding tubes

This procedure can be performed with the master cylinder mounted in position on the vehicle. However, it is most commonly performed with the master cylinder mounted in a soft jawed vise.

  1. Attach bleeder tubes to the cylinder outlet ports and insert tubes into the reservoir compartments. The bleeder tubes may be made up from brake line equipped with the correct master cylinder end fitting.
  3. Fill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 3 or DOT 4 specifications.
  5. If performing this procedure off the vehicle, insert a wooden dowel into the piston end of the cylinder. Otherwise, use the brake pedal to operate the master cylinder piston.
  7. Push the piston inward and release it. Continue this "pumping operation'' until no air bubbles are visible in the brake fluid.
  9. Correct the fluid level in the master cylinder as necessary.
  11. Remove the bleeder lines, install the reservoir caps and install the master cylinder.


See Figures 2, 3 and 4

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Fig. Fig. 2: Take extreme care when loosening the bleeder screw, if rusted, to avoid rounding it off

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