Removal & Installation
Non-ABS Equipped Models
See Figures 1, 2 and 3
- Disconnect and plug the brake lines.
- Remove the combination valve (if necessary).
- Remove all attaching bolts and nuts, and lift the assembly from the vehicle.
- Remove the protective cover from the end of the primary piston (if necessary).
- Clean the cylinder mounting surface on the booster.
- Install the master cylinder onto the brake booster studs.
- Install the nuts and tighten to 18 ft. lbs. (25 Nm).
- Connect the brake lines, fill the reservoir and bleed the brake system.
See Figures 4, 5, 6, 7, 8, 9, 10 and 11
This procedure applies to all models equipped with ABS except for 1989-91 Jeep models which are equipped with a Bendix anti-lock brake system. Refer to that removal procedure later in this section.
- Disengage the pedal travel sensor wires and remove the air cleaner.
- Before disconnecting any brake lines, suck out as much of the brake fluid as possible from the reservoir.
- Remove the clamps that secure the reservoir hoses to the Hydraulic Control Unit (HCU) pipes.
- Drain the fluid into a container and discard the fluid.
- Pump the brake pedal to exhaust all vacuum from the booster.
- Disengage the brake lines and the combination valve bracket bolt at the master cylinder.
- Unfasten the master cylinder attaching bolts and remove the master cylinder from the vehicle.
- If installing a new master cylinder, bleed the cylinder on a bench before installation.
- Install the master cylinder in position and engage the reservoir hoses to the HCU pipes.
- Tighten the master cylinder retaining bolts to 25 ft. lbs. (34 Nm) and connect the brake lines.
- Install the combination valve and bracket bolt (if removed).
- Connect the sensor wires and fill the reservoir.
- Bleed the brakes. Refer to the procedure outlined later in this section.
- Install the air cleaner and test drive the vehicle to verify proper brake operation.