Chrysler Full-Size Vans 1989-1998 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Rubber grommets seal the junction between the master cylinder housing and reservoir



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Fig. Fig. 2: Brake fluid will permanently damage the plastic grille, so avoid spilling brake fluid on the grille during servicing

The body of the master cylinder is made of aluminum and the reservoir is made of nylon. The body of the master cylinder is not serviceable, and should be replaced as a unit if defective.

  1. Using a flare nut wrench, loosen the brake line fittings on the master cylinder.
  2.  
  3. Disconnect and cap the brake lines to prevent dirt from entering the system.
  4.  
  5. On some vehicles, it will be necessary to remove the anti-lock brake valve or combination valve from the master cylinder.
  6.  
  7. Remove the master cylinder mounting nuts.
  8.  
  9. Slide the master cylinder off of the power brake booster.
  10.  

To install:
  1. If a new master cylinder is being installed, perform the master cylinder bleeding procedure, prior to installation.
  2.  
  3. Place the master cylinder in position on the brake booster and tighten the mounting nuts to 13-15 ft. lbs. (19-12 Nm).
  4.  
  5. Install the anti-lock brake valve or combination valve, if removed. Tighten the mounting nut to 54-94 inch lbs. (6-11 Nm).
  6.  
  7. Connect the brake lines and tighten fittings with a flare nut wrench to 11-15 ft. lbs. (15-12 Nm).
  8.  
  9. Refill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 2 or DOT 3 specifications. Properly bleed the brake system.
  10.  



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Fig. Fig. 3: Make sure you label the lines to the master cylinder upon removal to ease installation



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Fig. Fig. 4: The master cylinder is bolted to the booster, and is secured by two retaining bolts



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Fig. Fig. 5: If so equipped, detach the anti-lock brake valve before removing the master cylinder



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Fig. Fig. 6: Pull the master cylinder off the pushrod and power booster assembly

 
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