Ram Truck 1500, 2500 & 3500 (2006-2008)

Master Cylinder

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Removal & Installation



Except Hydro-Boost
  1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit.
  2.  
  3. Siphon and drain the fluid from the reservoir.
  4.  
  5. Disconnect the electrical connector for the low fluid level.
  6.  
  7. Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage.
  8.  
  9. Remove the brake lines from the master cylinder.
  10.  
  11. Remove the mounting nuts from the master cylinder.
  12.  
  13. Remove the master cylinder.
    NOTE
    Gently ease the master cylinder & reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod from its seat inside the booster.

  14.  

To install:


NOTE
If master cylinder is replaced bleed cylinder before installation.

  1. Install the master cylinder on the mounting studs.
    WARNING
    Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder.

  2.  
  3. Install new mounting nuts and tighten to 221 inch lbs. (25 Nm).
  4.  
  5. Install the brake lines and tighten to 170 inch lbs. (19 Nm).
  6.  
  7. Reconnect the electrical connector for the low fluid level switch.
  8.  
  9. Fill and bleed the base brake system.
  10.  

Hydro-Boost
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the brake lines from the master cylinder.
  4.  
  5. Disconnect the electrical connector for the low fluid level.
  6.  
  7. Remove the mounting nut from bottom of the master cylinder.
  8.  
  9. Unclip the wiring box next to the master cylinder and move out of the way.
  10.  
  11. Remove the upper mounting nut for the master cylinder.
  12.  
  13. Remove the master cylinder.
  14.  
  15. Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster.
  16.  

To install:


NOTE
If master cylinder is replaced bleed cylinder before installation.

  1. Install the master cylinder on the booster mounting studs.
  2.  
  3. Install a new upper mounting nut and tighten to 221 inch lbs. (25 Nm).
  4.  
  5. Reinstall the wiring box back into position and re-clip.
  6.  
  7. Install a new lower mounting nut and tighten to 221 inch lbs. (25 Nm).
  8.  
  9. Install the brake lines and tighten to 170 inch lbs. (19 Nm).
  10.  
  11. Reconnect the electrical connector for the low fluid level switch.
  12.  
  13. Fill and bleed the base brake system.
  14.  

 
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