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Chrysler Full-Size Vans 1989-1998 Repair Guide

Master and Slave Cylinders

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REMOVAL & INSTALLATION



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Clutch hydraulic linkage and pedal assembly

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the nuts attaching the slave cylinder to the bell housing.
  4.  
  5. Remove the slave cylinder and clip from the housing.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the locating clip from the clutch master cylinder mounting bracket.
  10.  
  11. Remove the retaining ring, flat washer, and wave washer that attach the clutch master cylinder pushrod to the clutch pedal. Slide the pushrod off the pedal pin.
  12.  
  13. Inspect the bushing on the pedal pin and replace if it is excessively worn.
  14.  

Verify that the cap on the clutch master cylinder reservoir is tight so that fluid will not spill during removal.

  1. Remove the screws attaching the reservoir and bracket to the dash panel and remove the reservoir.
  2.  
  3. Pull the clutch master cylinder rubber seal from the dash panel.
  4.  
  5. Rotate the clutch master cylinder, remote reservoir, slave cylinder and connecting lines from the vehicle.
  6.  

To install:
  1. Verify that the cap on the fluid reservoir is tight so that fluid will not spill during installation.
  2.  
  3. Insert the master cylinder in the dash. Rotate it 45 to lock it in place.
  4.  
  5. Lubricate the rubber seal to ease installation.
  6.  
  7. Seat the seal around the cylinder in the dash.
  8.  
  9. Install the fluid reservoir and bracket, if equipped, to the dash panel. Tighten screws to 40 inch lbs. (5 Nm).
  10.  
  11. Install the master cylinder pushrod to the clutch pedal pin. Secure the rod with the wave washer, flat washer and retaining ring. Install the locating clip.
  12.  

Do not remove the plastic shipping stop from the pushrod until the slave cylinder has been installed.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Insert the slave cylinder pushrod through the opening and make sure the cap on the end of the pushrod is securely engaged in the release lever before tightening the attaching nuts. Tighten the nuts to 17 ft. lbs. (23 Nm).
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the plastic shipping stop from the master cylinder pushrod.
  8.  
  9. Bleed the hydraulic system.
  10.  
  11. Operate the clutch pedal a few times to verify proper operation of the system.
  12.  

HYDRAULIC SYSTEM BLEEDING



The hydraulic linkage system is serviced as an assembly only. The individual components that form the system cannot be overhauled or serviced separately. The cylinders and connecting lines are sealed units.

 
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