torque DODGE NEON 1999 Service Workshop Manual

INSTALL
(1) Install park brake cable into floor pan of vehi-
cle making sure sealing grommet is installed in floor
pan as far as possible to insure proper seal.
(2) Install park brake cable into brake support
plate or rear disc brake adapter. Be sure locking tabs
on cable retainer are expanded to ensure park brake
cable is securely held in support plate or adapter.
(3) Install park brake cable routing bracket (Fig.
154) on frame rail. Install and securely tighten rout-
ing bracket attaching bolt.
(4)On vehicles equipped with rear drum
brakes,install park brake cable on park brake cable
actuating lever (Fig. 148). Then install actuating
spring between brake shoe assembly and brake
adjustment lever (Fig. 149).
(5)On vehicles equipped with rear disc
brakes,install park brake shoes actuator lever (Fig.
151) on park brake cable. Then install park brake
shoe assemblies on disc brake adapter (Fig. 150).
(6) Install the hub/bearing assembly on the rear
spindle. Then installA NEWrear hub/bearing
assembly retaining nut. Torque hub/bearing assembly
retaining nut to 217 N´m (160 ft. lbs.).
(7) Install hub/bearing assembly dust cap, using a
soft faced hammer.
(8) On drum brake equipped vehicles, install rear
brake drum on hub/bearing assembly. On vehicles
equipped with rear disc brakes, install rotor on hub/
bearing assembly.
(9) On disc brake equipped vehicles install disc
brake caliper on disc brake adapter. Install the 2 cal-
iper guide pin bolts (Fig. 156) and torque to 22 N´m
(192 in. lbs.). Refer To Rear Disc Brake Service in
this group of the service manual for the required cal-
iper installation procedure.
(10) Install rear wheel and tire assembly on vehi-
cle. Tighten all wheel stud nuts in criss cross pattern
Fig. 153 Park Brake Cable Removal From Disc
Brake Adapter
Fig. 154 Park Brake Cable Routing Bracket
Fig. 155 Park Brake Cable Seal At Floor PanFig. 156 Rear Caliper Guide Pin Bolts
5 - 54 BRAKESPL

to one-half specified torque. Then repeat pattern,
fully tightening stud nuts to 135 N´m (100 ft. lbs.).
(11) Lower vehicle.
(12) Grasp park brake cable to floor pan seal
grommet (Fig. 157) by hand, and pull it into floor
pan to ensure seal grommet is fully seated into floor
pan.
(13) Route park brake cable under carpeting and
up to park brake cable retaining bracket on floor
pan. Then install park brake cable into retaining
bracket (Fig. 158). Be sure tabs (Fig. 158) on park
brake cable retainer, have expanded out to hold park
brake cable in retaining bracket.
(14) Install rear park brake cables into equalizer
(Fig. 140) on park brake lever cable.
(15) Reposition rear carpeting.
(16) Install both rear door sill plate scuff moldings,
by snapping them onto rear door sills.(17) Install lower rear seat cushion. Be sure lower
seat cushion is fully installed in retainers on floor
pan of vehicle.
(18) Firmly grasp park brake lever locking pin
(3/16 in. drill bit) (Fig. 159) and quickly remove it
from the park brake lever mechanism. This will
allow the park brake lever mechanism to correctly
adjust the park brake cables.
(19) Cycle park brake lever ounce to position park
brake cables. Then return the park brake lever its
released position. Check the rear wheels of the vehi-
cle, they should rotate freely without dragging.
(20) Apply park brake to full engagement.
(21) Install center console assembly.
(22) Install the center console assembly attaching
screws.
PARK BRAKE SHOES WITH REAR DISC BRAKES
REMOVE
(1) Remove rear disc brake caliper assembly from
adapter and rotor (See Disc Brake Shoe Removal).
(2) Remove rear rotor from rear hub.
(3) Remove dust cap from rear hub.
(4) Remove rear hub and bearing assembly retain-
ing nut and washer.
(5) Remove rear hub and bearing assembly from
rear spindle.
(6) Remove rear brake shoe assembly hold down
clip (Fig. 160).
(7) Turn brake shoe adjuster wheel until adjuster
is at shortest length.
(8) Remove adjuster assembly from the parking
brake shoe assemblies (Fig. 161).
(9) Remove lower shoe to shoe spring (Fig. 162).
(10) Pull rear brake shoe assembly away from
anchor. Then remove rear brake shoe and upper
spring (Fig. 163).
Fig. 157 Seal Grommet Installation In Floor Pan
Fig. 158 Park Brake Cable Installed In Retaining
Bracket
Fig. 159 Removing Lockout Pin From Park Brake
Lever
PLBRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)

(9) InstallA NEWhub and bearing assembly
retaining nut. Torque the hub and bearing assembly
retaining nut to 168 N´m (124 ft. lbs.).
(10) Install hub and bearing assembly dust cap.
(11) Install rear rotor.
(12) Install rear disc brake caliper on the adapter
(See Brake Shoe Removal).
(13) Install wheel and tire assemblies.
(14) Tighten wheel stud nuts to 129 N´m (95
ft.lbs.).
STOP LAMP SWITCH
REMOVE
(1) Depress and hold the brake pedal while rotat-
ing stop lamp switch (Fig. 165) in a counter-clockwise
direction approximately 30 degrees.
(2) Pull the switch rearward and remove from its
mounting bracket.
(3) Disconnect wiring harness connector from stop
lamp switch.
INSTALL
NOTE: Prior to installing stop lamp switch into
bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
(1) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(2) Connect the wiring harness connector to the
stop lamp switch.(3) Mount the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then install switch in
bracket by aligning index key on switch with slot at
top of square hole in mounting bracket. When switch
is fully installed in bracket, rotate switch clockwise
approximately 30É to lock switch into bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If to much force is used, damage to the stop lamp
switch or striker (Fig. 165) can result.
(4) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger to
ratchet backward to the correct position.
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID RESERVOIR
NOTE: The master cylinder does not need to be
removed from the power brake vacuum booster for
replacement of the brake fluid reservoir.
(1) Clean master cylinder housing and brake fluid
reservoir.
(2) Remove the brake fluid reservoir cap. Using a
CLEANsyringe or equivalent type tool, empty as
much brake fluid as possible from the reservoir.
NOTE: Do not pry off using a tool, damage to res-
ervoir may result.
(3) Rock brake fluid reservoir from side to side
while pulling up to remove the reservoir from the
master cylinder housing (Fig. 166).
(4) Remove master cylinder housing to brake fluid
reservoir grommets.
Fig. 164 Front Hold Down Clip And Brake Shoe
Fig. 165 Stop Lamp Switch
PLBRAKES 5 - 57
REMOVAL AND INSTALLATION (Continued)

(12) Inspect caliper piston for pitting, scratches, or
any physical damage. Replace piston if there is evi-
dence of scratches, pitting or physical damage.
CALIPER ASSEMBLY
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
(1) Clamp caliper in a vise (with protective caps
installed on jaws of vise).
(2) Dip new piston seal in clean brake fluid and
install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove (Fig. 180), using only your
fingers until properly seated.NEVER USE AN OLD
PISTON SEAL.Be sure that fingers are clean and
seal is not twisted or rolled (Fig. 180).
(3) Coat new piston boot with clean brake fluid
leaving a generous amount inside boot.
(4) Position dust boot over piston after coating
with brake fluid.
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
(5) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 181).
(6) Position dust boot into the counterbore of the
caliper assembly piston bore.
(7) Using a hammer and Installer Piston Caliper
Boot, Special Tool C-4689 and Handle, Special ToolC-4171, drive boot into counterbore of the caliper
(Fig. 182).
(8) Install guide pin sleeves and bushings. See
Install Guide Pin Bushings section in the caliper dis-
assembly section of this manual.
(9) Install brake pads. See Installing Brake Pads
in the Brake Pad Service Procedures section of this
manual.
(10) Before installing caliper assembly on vehicle,
inspect brake rotor. If any conditions as described in
Checking Brake Rotor for Runout and Thickness are
present the rotor, must be replaced or refaced. If the
rotor does not require any servicing, install caliper
assembly.
(11) Install brake hose onto caliper using banjo
bolt. Torque the brake hose to caliper assembly banjo
bolt to 33 N´m (24 ft. lbs.).New seal washers
Fig. 179 Honing Brake Caliper Piston Bore
Fig. 180 Installing New Piston Seal In Caliper
Fig. 181 Installing Piston Into Caliper Bore
5 - 62 BRAKESPL
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Remove the rubber plug from the adjusting
hole in the brake shoe backing plate on both sides of
the vehicle.
(4)Driver (left) side park brake shoe adjust-
ment procedure.Insert a medium size screwdriver
through adjustment hole in backing plate. Position
the srewdriver against the starwheel on the park
brake shoe adjuster mechanism. Using the screw-
driver rotate the starwheeldownwarduntil a slight
drag is felt when turning the rear tire and wheel.
Then, using the screwdriver rotate the starwheel
upwardjust until the rear tire and wheel can be
rotated with no park brake shoe drag. From the
point where there is no more park brake drag rotate
the starwheelupwarda maximum of two additional
clicks. The park brake shoe to drum clearance is
know properly adjusted.
(5)Passenger (right) side park brake shoe
adjustment procedure.Insert a medium size
screwdriver through adjustment hole in backing
plate. Position the srewdriver against the starwheel
on the park brake shoe adjuster mechanism. Using
the screwdriver rotate the starwheelupwarduntil a
slight drag is felt when turning the rear tire and
wheel. Then, using the screwdriver rotate the star-
wheeldownwardjust until the rear tire and wheel
can be rotated with no park brake shoe drag. From
the point where there is no more park brake drag
rotate the starwheeldownwarda maximum of two
additional clicks. The park brake shoe to drum clear-
ance is know properly adjusted.
(6) Install the rubber plug in the adjusting hole on
the brake shoe backing plate on both sides of the
vehicle.
(7) Lower vehicle far enough to allow access the
park brake lever. The rear tires must not be on the
ground.
(8) Fully apply and release the park brakes two
times after adjusting the park brake shoes. Then
rotate both rear wheels to ensure that the park
brake shoes do not drag on the brake drum following
the application and release of the park brakes.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. Anopen container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
MASTER CYLINDER ASSEMBLY:
Type ...........................Dual Tandem
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE / STROKE
AND SPLIT:
NonABS ....21mmx32.6 mm (.875 in. x 1.28 in.)
ABS........21mmx32.7 mm (.874 in. x 1.29 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
ABS ..........Primary 3/8±24 Secondary 7/16±24
Non ABS . . .Primary Inboard And Outboard 7/16±24
Non ABS . . .Secondary Inboard And Outboard 3/8±23
Outlet Fitting Type.......SAE 45 É Inverted Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type.SAE 45 É Inverted Flare
BOOSTER:
Make/Type.........Bendix Vacuum W/&W/O ABS
Mounting Studs.....................M8x1.25
Type ..........................230 mm Single
Boost At 20 inches Of Manifold Vacuum. . . .4690 All
PROPORTIONING VALVE:
Material...........................Aluminum
Function........Hydraulic Pressure Proportioning
BRAKE PEDAL
Pedal Ratio.............................3.28
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components Except HCU. . . . 17 N´m (145 in. lbs.)
From Master Cylinder To
HCU At HCU Ports........21N´m(185 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
PLBRAKES 5 - 67
ADJUSTMENTS (Continued)

DESCRIPTION TORQUE
MASTER CYLINDER:
To Vacuum Booster Mounting Nut.28 N´m (250 in. lbs.)
BRAKE BOOSTER:
To Dash Panel Mounting Nuts . .28 N´m (250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate Mounting Bolts.13 N´m (115 in. lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
REAR DISC BRAKE ADAPTER:
To Axle Mounting Bolts.........75N´m(55ft.lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts.............22N´m(192 in. lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
To Mounting Bracket Bolts.....28N´m(250 in. lbs.)
Bracket To Frame Rail Mounting Bolt (Top) . .18 N´m
(160 in. lbs.)
Bracket To Frame Rail Mounting Bolts (Side).22 N´m
(200 in. lbs.)
PARKING BRAKE:
Lever Mounting Nuts.........28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Knuckle Retaining Nut.....217 N´m (160 ft. lbs.)
WHEEL:
Stud Lug Nut........109±150 N´m (80±110 ft. lbs.)
SPECIAL TOOLS
BASE BRAKE SYSTEM
Adapters, Brake Pressure Test 6805
Gauge Set C-4007-A
Handle, Universal C-4171
Installer, Dust Boot C-4689
Dial Indicator C-3339
Tubes, Master Cylinder Bleeding 6802
5 - 68 BRAKESPL
SPECIFICATIONS (Continued)

ANTILOCK BRAKE SYSTEM±TEVES MARK 20
INDEX
page page
DESCRIPTION AND OPERATION
ABS BRAKE SYSTEM COMPONENTS........ 71
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE....................... 69
ABS COMPONENT ABBREVIATION LIST...... 69
ABS FLUID ACCUMULATORS.............. 72
ABS FUSES............................ 73
ABS MASTER CYLINDER AND POWER BRAKE
BOOSTER............................ 71
ABS RELAYS........................... 73
ABS WARNING LAMP (YELLOW)............ 75
ANTILOCK BRAKES OPERATION
DESCRIPTION........................ 69
CONTROLLER ANTILOCK BRAKES (CAB)..... 74
HCU PUMP/MOTOR..................... 72
HYDRAULIC CIRCUITS AND VALVE
OPERATION.......................... 75
INLET VALVES AND SOLENOIDS............ 72
INTEGRATED CONTROL UNIT (ICU)......... 71
OUTLET VALVES AND SOLENOIDS.......... 72
PROPORTIONING VALVE................. 73
WHEEL SPEED SENSORS................. 73
DIAGNOSIS AND TESTING
ABS DIAGNOSTIC TROUBLE CODES........ 78
ABS DIAGNOSTICS MANUAL.............. 76
ABS GENERAL DIAGNOSTICS INFORMATION . 75
ABS SERVICE PRECAUTIONS.............. 76
ABS SYSTEM SELF DIAGNOSTICS.......... 77ABS WIRING DIAGRAM INFORMATION....... 76
BRAKE FLUID CONTAMINATION............ 80
DRB DIAGNOSTIC CONNECTOR............ 77
DRB DIAGNOSTIC SCAN TOOL USAGE...... 77
INTERMITTENT DIAGNOSTIC TROUBLE
CODES.............................. 78
PROPORTIONING VALVE................. 79
TEST DRIVING ABS COMPLAINT VEHICLE.... 80
TONEWHEEL INSPECTION................ 79
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM............................. 81
BRAKE FLUID LEVEL INSPECTION.......... 80
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS..... 81
ABS HYDRAULIC CONTROL UNIT........... 82
CONTROLLER ANTILOCK BRAKES (CAB)..... 86
FRONT WHEEL SPEED SENSOR........... 87
MASTER CYLINDER AND POWER BRAKE
BOOSTER............................ 86
PROPORTIONING VALVES................ 86
REAR WHEEL SPEED SENSOR............ 88
SPECIFICATIONS
BRAKE FASTENER TORQUE SPECIFICATIONS . 89
SPEED SENSOR TONE WHEEL RUNOUT..... 89
WHEEL SPEED SENSOR TO TONE WHEEL
CLEARANCE.......................... 89
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Antilock Brake System (ABS) is
to prevent wheel lock-up under braking conditions on
virtually any type of road surface. Antilock Braking
is desirable because a vehicle which is stopped with-
out locking the wheels will retain directional stability
and some steering capability. This allows the driver
to retain greater control of the vehicle during brak-
ing.
This section of the service manual covers the
description and on car service for the ITT Teves
Mark 20 ABS Brake System. If other service is
required on the non ABS related components of the
brake system, refer to the appropriate section in this
group of the service manual for the specific service
procedure required.
ABS COMPONENT ABBREVIATION LIST
In this section of the service manual, several
abbreviations are used for the components of the
Teves Mark 20 ABS Brake System. They are listed
below for your reference.
²CAB±Controller Antilock Brake
²ICU±Integrated Control Unit
²HCU±Hydraulic Control Unit
²ABS±Antilock Brake System
²PSI±Pounds Per Square Inch (pressure)
²WSS±Wheel Speed Sensor
²FWD±Front Wheel Drive
²DTC±Diagnostic Trouble Code
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE
This ABS System represents the current state-of-
the-art in vehicle braking systems and offers the
driver increased safety and control during braking.
PLBRAKES 5 - 69

For the specific procedure covering the inspection
of the brake fluid level and adding brake fluid to the
reservoir, refer to the Service Adjustments Section in
this group of the service manual.
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM
The hydraulic system for the base brakes must be
bled anytime air enters the hydraulic system. Air can
enter the hydraulic system for the base brakes due to
the disconnection of brake lines, hoses or any other
hydraulically operated component of the base brake
system. The ABS system, particularly the ICU,
should only be bled when the ICU is replaced or it is
removed from the vehicle. The ICU must also always
be bled if for any reason it is suspected that the ICU
has ingested air. Under most circumstances that
require the bleeding of the brakes hydraulic system,
only the base brake hydraulic system needs to be
bled.
It is important to note that excessive air in the
brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the
brake fluid level remains close to the FULL level in
the master cylinder fluid reservoir. Check the fluid
level periodically during the bleeding procedure and
add DOT 3 brake fluid as required.
The ITT Teves Mark 20 ABS must be bled as two
independent braking systems. The non ABS portion
of the brake system is to be bled the same as any
non ABS system. Refer to the Service Adjustments
section in this manual for the proper bleeding proce-
dure to be used. This brake system can be either
pressure bled or manually bled.
The ABS portion of the brake system MUST be
bled separately. This bleeding procedure requires the
use of the DRB Diagnostic Tester and the bleeding
sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following
bleeding sequenceMUSTbe followed to insure com-
plete and adequate bleeding. The ABS system can be
bled using a manual bleeding procedure or standard
pressure bleeding equipment.
If the brake system is to be bled using pressurized
bleeding equipment, refer to Bleeding Brake System
in the Service Adjustments section at the beginning
of this group for proper equipment usage and proce-
dures.
(1) Assemble and install all brake system compo-
nents on the vehicle making sure all hydraulic fluid
lines are installed and properly torqued.
(2) Connect the DRB Diagnostics Tester to the
diagnostics connector. The Teves Mark 20 ABS diag-
nostic connector is located under the instrument
panel to the left of the steering column cover.(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does,
remove them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYS-
TEM WEAR SAFETY GLASSES. A CLEAR BLEED
TUBE MUST BE ATTACHED TO THE BLEEDER
SCREWS AND SUBMERGED IN A CLEAR CON-
TAINER FILLED PART WAY WITH CLEAN BRAKE
FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY
FROM THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME
OUT OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure as out-
lined in the Service Adjustments section of this
service manual.
(5) Using the DRB, go to the9Bleed ABS9routine.
Apply the brake pedal firmly and initiate the9Bleed
ABS9cycle one time. Release the brake pedal.
(6) Bleed the base brake system again, as in step
Step 4 above.
(7) Repeat steps Step 5 and Step 6 above until
brake fluid flows clear and is free of any air bubbles.
Check brake fluid level in reservoir periodically to
prevent reservoir from running low on brake fluid.
(8) Test drive the vehicle to be sure brakes are
operating correctly and that the brake pedal does not
feel spongy.
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS
CAUTION: Review this entire section prior to per-
forming any mechanical work on a vehicle equipped
with the ITT Tevis Mark 20 ABS brake system. This
section contains information on precautions per-
taining to potential component damage, vehicle
damage and personal injury which could result
when servicing an ABS equipped vehicle.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
PLBRAKES 5 - 81
SERVICE PROCEDURES (Continued)

INSTALL
(1) Install the ICU on the mounting bracket.
(2) Install the 3 bolts attaching the HCU to the
mounting bracket (Fig. 25).
(3) Tighten the 3 mounting bolts to a torque of 11
N´m (97 in. lbs.)
CAUTION: Before installing the 25 way connector
in the CAB be sure that the seal is properly
installed in the connector.
(4) Install the 25 way connector into the socket on
the CAB. The connector is installed using the follow-
ing procedure. Position the 25 way connector in the
socket on the CAB and carefully push it down as far
as it will go. When connector is fully seated into the
CAB socket push in the connector lock (Fig. 24) as
far as it will go. This will pull the 25 connector into
the socket on the CAB and lock it in the installed
position.
(5) Install the 4 chassis brake tubes (Fig. 23) into
the outlet ports on the HCU.(6) Using a crow foot (Fig. 26) tighten the 4 chas-
sis brake tube nuts to a torque of 17 N´m (145 in.
lbs.).
NOTE: When installing the master cylinder brake
tubes on the HCU, the brake tube with the small
tube nut is to be installed in the front inlet port of
the HCU. This is the port on the HCU that is toward
the front of the vehicle. Also, when installing the
brake tubes correctly position them for installation
into master cylinder.
(7) Install the primary and secondary brake tubes
(Fig. 22) from the master cylinder onto the HCU.
(8) Using a crow foot as shown in Step 6 tighten
the 2 chassis brake tube nuts to a torque of 17 N´m
(145 in. lbs.).
(9) Remove vacuum seal (Fig. 27) located in the
front of the power brake vacuum booster. Vacuum
seal is removed bycarefullyinserting a small screw
driver between the push rod of the power brake vac-
uum booster and vacuum seal (Fig. 27) and pry seal
out of power brake vacuum booster.Do not attempt
to pry seal out of master cylinder by inserting a
tool between seal and power brake vacuum
booster.
(10) Remove old vacuum seal from master cylinder,
if the vacuum seal came out of power brake vacuum
booster when master cylinder was removed.
CAUTION: When replacing the master cylinder on
a vehicle equipped with ABS, a NEW vacuum seal
MUST be installed in the power brake vacuum
booster. Use only the procedure detailed below for
installing vacuum seal into power brake vacuum
booster. Be sure old vacuum seal is removed from
power brake vacuum booster before attempting to
install new seal.
Fig. 24 Unlocked CAB Connector
Fig. 25 Hydraulic Control Unit Mounting Bracket
Fig. 26 Torquing Chassis Tube Nuts At HCU
5 - 84 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

CAUTION: When lubricating master cylinder push
rod, use only Mopar Silicone Dielectric Compound.
Using any other type of grease or lubricant on the
push rod, will not provide adequate long term lubri-
cation of the push rod.
(11) Lubricate master cylinder push rod as indi-
cated in (Fig. 28) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(12) Install vacuum seal on master cylinder push
rod as shown in (Fig. 29) with notches on vacuum
seal pointing toward master cylinder housing. Then
slide vacuum seal onto master push rod until seal is
seated against master cylinder housing (Fig. 30)
before installing master cylinder on power brake vac-
uum booster.
CAUTION: Be sure old vacuum seal is removed
from power brake vacuum booster before attempt-
ing to install master cylinder and NEW vacuumseal. If vacuum seal is not removed, refer to Master
Cylinder Removal in this section of the service
manual for required vacuum seal removal proce-
dure.
(13) Position master cylinder on studs of vacuum
booster aligning push rod on vacuum booster with
master cylinder push rod.
(14) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 21). Tighten the mounting
nuts to a torque of 28 N´m (250 in. lbs.) torque.
(15) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 20). Torque all tube
nuts to 17 N´m (145 in. lbs.) torque.
(16) Using a crow foot (Fig. 31) tighten the brake
tube nuts at the master cylinder to a torque of 17
N´m (145 in. lbs.).
(17) Install the wiring harness connector on the
master cylinder reservoir fluid level switch.
Fig. 27 Removing Vacuum Seal From Vacuum
Booster
Fig. 28 Lubricating Master Cylinder Push Rod
Fig. 29 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 30 Vacuum Seal Positioned For Installing
Master Cylinder
PLBRAKES 5 - 85
REMOVAL AND INSTALLATION (Continued)