Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Master Cylinder

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Fig. Fig. 1 Master cylinder exploded view

REMOVAL & INSTALLATION



With Power Brakes
  1. Disconnect the primary and secondary brake lines from the master cylinder. Plug the openings.
  2.  
  3. Remove the nuts attaching the cylinder to the power brake booster.
  4.  
  5. Slide the master cylinder straight out, away from the booster.
  6.  

To install:

  1. Position the master cylinder over the studs on the booster, align the pushrod with the master cylinder piston and tighten the nuts to 16 ft. lbs. (22 Nm).
  2.  



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Fig. Fig. 2 On vehicles equipped with power brakes, the master cylinder is mounted to the booster

  1. Connect the brake lines.
  2.  
  3. Bleed the brakes.
  4.  

Without Power Brakes
  1. Disconnect the primary and secondary brake lines and install plugs in the master cylinder openings.
  2.  



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Fig. Fig. 3 Whenever possible, use a flare wrench to disconnect the master cylinder brake lines

  1. Disconnect the stoplight switch mounting bracket from under the instrument panel.
  2.  
  3. Pull the brake pedal backward to disengage the pushrod from the master cylinder piston.
  4.  


WARNING
This will destroy the grommet. Use a new one when installing the master cylinder.

  1. Remove the master cylinder-to-firewall nuts.
  2.  



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Fig. Fig. 4 Remove the master cylinder-to-firewall nuts

  1. Slide the master cylinder out and away from the firewall. Be sure to remove all pieces of the broken grommet.
  2.  

To install:

  1. Install the boot on the pushrod.
  2.  
  3. Install a new grommet on the pushrod.
  4.  
  5. Apply a soap and water solution to the grommet and slide it firmly into position in the primary piston socket. Move the pushrod from side to side to make sure it's seated.
  6.  
  7. From the engine side, press the pushrod through the master cylinder mounting plate and align the mounting studs with the holes in the cylinder.
  8.  
  9. Install the nuts and tighten them to 16 ft. lbs. (22 Nm).
  10.  
  11. From under the instrument panel, place the pushrod on the pin on the pedal and install a new retaining clip.
  12.  


WARNING
Be sure to lubricate the pin.

  1. Install the brake lines on the master cylinder.
  2.  
  3. Bleed the system.
  4.  

OVERHAUL




CAUTION
Do not hone the master cylinder bore. Honing will remove the anodized finish.

  1. Clean the housing and reservoir.
  2.  
  3. Remove the reservoir caps and empty the fluid.
  4.  
  5. Clamp the master cylinder in a soft-jawed vise.
  6.  
  7. Pull the reservoir from the master cylinder housing.
  8.  



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Fig. Fig. 5 Carefully mount the master cylinder in a vise, then pull the reservoir from the cylinder housing

  1. Remove the reservoir grommets.
  2.  



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Fig. Fig. 6 Remove the reservoir grommets

  1. Use needle-nosed pliers to remove the secondary piston pin from inside the housing.
  2.  



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Fig. Fig. 7 Use needle-nosed pliers to remove the secondary piston pin from inside the housing

  1. Remove the snapring from the outer end of the housing.
  2.  
  3. Slide the primary piston out of the master cylinder bore.
  4.  



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Fig. Fig. 8 After removing the snapring from the housing, slide the primary piston out of the master cylinder bore

  1. Tap the open end of the cylinder on the bench to remove the secondary piston. If it sticks