PT Cruiser 2006-2007

Master Cylinder

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Removal & Installation




NOTE
Vehicles equipped with a Non-Turbo engine have one-piece master/slave cylinder assemblies. If the master cylinder requires replacement, the master AND slave cylinders must be replaced with a two-piece -quick-connect- system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.


NOTE
Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly.

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Turbo-equipped models: Using Tool 6638A, disconnect clutch hydraulic quick-connect.
  8.  
  9. Non-Turbo models: Remove slave cylinder from transaxle.
  10.  
  11. Remove hydraulic hose from left rail retainer.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Remove PDC bracket and position out of way.
  16.  
  17. Remove lower instrument panel bezel.
  18.  
  19. Remove clip and disconnect the brake booster input rod from the brake pedal pin.
  20.  
  21. Remove the brake booster mounting nuts.
  22.  
  23. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
  24.  
  25. Remove clutch master cylinder reservoir.
  26.  
  27. Disconnect clutch master cylinder pushrod from clutch pedal. Inspect retainer bushing and replace if damaged in any way.
  28.  
  29. Remove two clutch master cylinder retaining nuts.
    WARNING
    Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.


    WARNING
    Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.

  30.  
  31. Remove the master cylinder assembly from the mounting position and carefully work the hydraulic pipe from out of the engine compartment. Non-Turbo equipped vehicles: If master cylinder is being replaced, it is necessary to cut hydraulic tube, breaking system into 2 pieces for easy removal.
  32.  

To install:

Click image to see an enlarged view

Fig. Clutch master cylinder mounting points

  1. Install clutch master cylinder into position and carefully route hydraulic pipe into position as removed.
  2.  
  3. Install clutch master cylinder reservoir.
  4.  
  5. Install and torque 2 clutch master cylinder-to-dash panel retaining nuts to 130 inch lbs. (15 Nm) torque.
  6.  
  7. Loosen master cylinder pushrod adjustment screw.
  8.  
  9. Connect clutch master cylinder rod to clutch pedal pin. An audible -click- should be heard. If damaged, replace nylon retainer.
  10.  
  11. Adjust clutch pedal position. Gently lift upward on clutch pedal. Tighten adjustment screw to 55 inch lbs. (6 Nm) torque.
  12.  
  13. Install brake booster into position. Connect push rod to brake pedal pin.
  14.  
  15. Install and torque brake booster-to-cowl panel nuts to 25 ft. lbs. (34 Nm).
  16.  
  17. Install push rod retaining clip.
  18.  
  19. Replace stop lamp switch. Refer to Stop Lamp Switch Removal and Installation.
  20.  
  21. Install lower instrument panel bezel.
  22.  
  23. Install PDC bracket into position.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Install clutch master cylinder hydraulic pipe into left rail retainer.
  28.  
  29. If master cylinder is being replaced, also install service replacement slave cylinder. If original master cylinder is being re-used, install slave cylinder.
  30.  
  31. Turbo Models: Connect hydraulic pipe to clutch slave cylinder. An audible -click- should be heard. Verify connection by pulling outward on connection.
  32.  
  33. Carefully lower the vehicle.
  34.  
  35. Connect battery negative cable.
  36.  
  37. Install air cleaner assembly.
  38.  
  39. Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary.
  40.  
  41. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system.
  42.  
  43. Verify proper clutch release system operation.
  44.  

 
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