vacuum DODGE NEON 1999 Service Repair Manual

BRAKES
CONTENTS
page page
ANTILOCK BRAKE SYSTEM±TEVES MARK 20 . 69
BASE BRAKE SYSTEM..................... 2GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page
GENERAL INFORMATION
BASE BRAKE SYSTEM DESCRIPTION........ 1
GENERAL INFORMATION
BASE BRAKE SYSTEM DESCRIPTION
Typical brake equipment consists of:
²Double pin floating caliper disc front brakes.
²Rear automatic adjusting drum brakes.
²Brake Fluid Level Switch.
²Master cylinder.
²Vacuum power booster.
²Double pin floating caliper rear disc brakes are
available on some models.
²Hand operated auto adjust park brake lever.
²Front disc brake pads are semi-metallic.
Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20 and
is supplied by Teves. This system shares the base
brake hardware with vehicles not equipped withABS. A vehicle equipped with ABS does however use
a different vacuum booster, master cylinder and
brake tubes. Also included in the ABS system is an
integrated control unit (ICU), four wheel speed sen-
sors, and an electronic controller referred to as the
controller antilock brakes (CAB). These components
will be described in detail in the Teves Mark 20 ABS
brake section in this group of the service manual.
The hydraulic brake system is diagonally split on
both the Non-ABS and ABS braking system. With the
left front and right rear brakes on one hydraulic sys-
tem and the right front and left rear on the other.
The master cylinder is anodized, lightweight alu-
minum. On vehicles equipped with front disc brakes
and rear drum brakes, the master cylinder bore is
21.0 mm. On vehicles equipped with four wheel disc
brakes, the master cylinder bore is 22.2 mm.
PLBRAKES 5 - 1

BASE BRAKE SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES.............. 6
FRONT DISC BRAKES..................... 2
MASTER CYLINDER...................... 6
PARKING BRAKES........................ 4
PROPORTIONING VALVES................. 5
REAR DISC BRAKES...................... 4
REAR DRUM BRAKES..................... 4
REAR WHEEL HUB/BEARING............... 8
RED BRAKE WARNING LAMP............... 7
STOP LAMP SWITCH...................... 8
VACUUM BOOSTER...................... 6
DIAGNOSIS AND TESTING
BRAKE FLUID CONTAMINATION............ 19
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE.... 9
BRAKE SYSTEM DIAGNOSIS CHARTS....... 10
DRUM BRAKE AUTOMATIC ADJUSTER....... 14
PROPORTIONING VALVES................ 16
RED BRAKE WARNING LAMP TEST......... 19
ROTOR THICKNESS AND RUNOUT.......... 14
STOP LAMP SWITCH TEST PROCEDURE..... 19
SERVICE PROCEDURES
BRAKE BLEEDING....................... 20
BRAKE DRUM MACHINING................ 23
BRAKE FLUID LEVEL CHECK.............. 19
BRAKE ROTOR MACHINING............... 22
BRAKE TUBE REPAIR.................... 25
MASTER CYLINDER BLEEDING............ 21
PARK BRAKE LEVER AUTO ADJUSTER
MECHANISM.......................... 23
REMOVAL AND INSTALLATION
CHASSIS TUBES AND HOSES.............. 47
FRONT DISC BRAKE CALIPER............. 26
FRONT DISC BRAKE SHOES.............. 28
MASTER CYLINDER..................... 41
PARK BRAKE CABLES.................... 50
PARK BRAKE LEVER ASSEMBLY........... 48PARK BRAKE LEVER OUTPUT CABLE....... 49
PARK BRAKE SHOES WITH REAR DISC
BRAKES............................. 55
PROPORTIONING VALVE (BASE BRAKES).... 47
REAR BRAKE DRUM..................... 34
REAR BRAKE SHOE SUPPORT PLATE....... 37
REAR BRAKE SHOES.................... 35
REAR BRAKE WHEEL CYLINDER........... 38
REAR DISC BRAKE CALIPER.............. 30
REAR DISC BRAKE SHOES................ 32
REAR HUB/BEARING..................... 39
STOP LAMP SWITCH..................... 57
VACUUM BOOSTER..................... 44
WHEEL AND TIRE ASSEMBLY.............. 26
DISASSEMBLY AND ASSEMBLY
BRAKE FLUID LEVEL SWITCH............. 58
BRAKE FLUID RESERVOIR................ 57
FRONT AND REAR DISC BRAKE CALIPER.... 58
WHEEL CYLINDER (REAR DRUM BRAKE).... 63
CLEANING AND INSPECTION
CHASSIS TUBES AND HOSES.............. 65
FRONT DISC BRAKES.................... 63
REAR DISC BRAKES..................... 64
REAR DRUM BRAKE WHEEL CYLINDER...... 65
REAR DRUM BRAKES.................... 64
REAR WHEEL HUB AND BEARING ASSEMBLY . 65
ADJUSTMENTS
PARK BRAKE ADJUSTMENT............... 66
REAR DRUM BRAKE SHOE ADJUSTMENT.... 65
STOP LAMP SWITCH..................... 65
SPECIFICATIONS
BRAKE ACTUATION SYSTEM.............. 67
BRAKE FASTENER TORQUE SPECIFICATIONS . 67
BRAKE FLUID.......................... 67
SPECIAL TOOLS
BASE BRAKE SYSTEM................... 68
DESCRIPTION AND OPERATION
FRONT DISC BRAKES
The front disc brakes (Fig. 1) and (Fig. 2) consists
of the following components:
²The driving hub
²Braking disc (rotor)
²Caliper assembly - single piston, floating type
²Brake shoes and linings
The double pin calipers are mounted directly to the
steering knuckles and use no adapter. The caliper ismounted to the steering knuckle using bushings,
sleeves and 2 guide pin bolts which thread directly
into bosses on the steering knuckle (Fig. 2) and (Fig.
3).
Two machined abutments on the steering knuckle
position the caliper. The guide pin bolts, sleeves and
bushings control the side to side movement of the
caliper. The piston seal is designed to pull the piston
back into the bore of the caliper when the brake
pedal is released. This maintains the proper brake
shoe to rotor clearance (Fig. 4).
5 - 2 BRAKESPL

portioning valve has a different part number. During
any service procedures identify valve assemblies by
supplier part number and or the color identification
band (Fig. 12).
CHASSIS TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The chassis tubes are steel with a corro-
sion resistant coating applied to the external surfaces
and the flex hoses are made of reinforced rubber. The
rubber flex hoses allow for the movement of the vehi-
cles suspension.
MASTER CYLINDER
This vehicle is available with three different mas-
ter cylinders. The vehicle uses screw-in proportioning
valves at the master cylinder or in-line proportioning
valves located in the rear chassis brake tubes instead
of a combination valve. With this new design, the
chassis brake tubes connect directly from the master
cylinder or HCU to the front and rear brake flex
hoses.
Vehicles not equipped with ABS use a standard
compensating port master cylinder, while vehicles
equipped with ABS use a center valve design mastercylinder. In addition, the non-ABS master cylinders
are a four outlet design with two screw-in proportion-
ing valves attached directly to the inboard side of the
master cylinder housing (Fig. 13). The ABS master
cylinder is a two outlet design (Fig. 14). The primary
and secondary outlet on the master cylinder are con-
nected directly to the hydraulic control portion of the
ICU (Fig. 14) Vehicles equipped with antilock brakes
use in-line proportioning valves mounted in the chas-
sis brake tubes going to the rear brakes. Vehicles
equipped with rear drum brakes use a master cylin-
der with a 21.0 mm bore diameter, while vehicles
equipped with rear disc brake use a 22.2 mm bore
master cylinder.
The master cylinder (Fig. 13) consists of the follow-
ing components. The body of the master cylinder is
an anodized aluminum casting. It has a machined
bore to accept the master cylinder piston and
threaded ports with seats for hydraulic brake line
connections. The brake fluid reservoir of the master
cylinder assembly is made of a see through type plas-
tic.
On Non-ABS master cylinders, the primary outlet
ports (Fig. 15) supply hydraulic pressure to the left
front and right rear brakes. The secondary outlet
ports (Fig. 15) supply hydraulic pressure to the right
front and left rear brakes.
On the ABS master cylinder, the primary outlet
port (Fig. 14) supplies hydraulic pressure to the right
front and left rear brakes. The secondary outlet port
(Fig. 14) supplies hydraulic pressure to the left front
and right rear brakes.
VACUUM BOOSTER
All vehicles use a 230 mm single diaphragm power
brake vacuum booster. There are however two differ-
ent booster designs; one for vehicles equipped with
ABS and one for vehicles without ABS. These two
Fig. 11 Antilock Proportioning Valve (Left Side
Shown)
Fig. 12 Antilock Proportioning Valve
Fig. 13 Master Cylinder For Non Antilock Brake
Equipped Vehicles
5 - 6 BRAKESPL
DESCRIPTION AND OPERATION (Continued)

boosters differ at the interface to the master cylinder.
If the power brake booster requires replacement be
sure it is replaced with the correct part.
The power brake booster can be identified by the
tag attached to the body of the booster assembly (Fig.
16). This tag contains the following information: The
production part number of the power booster assem-
bly, the date it was built, who manufactured it, and
brake sales code.
NOTE: The power brake booster assembly is not a
repairable part and must be replaced as a complete
unit if it is found to be faulty in any way. The power
booster vacuum check valve is not repairable but
can be replaced as an assembly.The power brake booster reduces the amount of
force required by the driver to obtain the necessary
hydraulic pressure to stop vehicle.
The power brake booster is vacuum operated. The
vacuum is supplied from the intake manifold on the
engine through the power brake booster check valve
(Fig. 16).
As the brake pedal is depressed, the power booster
input rod moves forward (Fig. 17). This opens and
closes valves in the power booster, allowing atmo-
spheric pressure to enter on one side of a diaphragm.
Engine vacuum is always present on the other side.
This difference in pressure forces the output rod of
the power booster (Fig. 17) out against the primary
piston of the master cylinder. As the pistons in the
master cylinder move forward this creates the
hydraulic pressure in the brake system.
Different engine options available for this vehicle
require that different vacuum hose routings be used.
The power brake vacuum booster assembly mounts
on the engine side of the dash panel. It is connected
to the brake pedal by the input push rod (Fig. 17). A
vacuum line connects the power booster to the intake
manifold. The master cylinder is bolted to the front
of the power brake vacuum booster assembly.
RED BRAKE WARNING LAMP
The red Brake warning lamp is located in the
instrument panel cluster and is used to indicate a
low brake fluid condition or that the parking brake is
applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch
when the ignition switch is placed in the crank posi-
tion. Problems with this system will generally be of
the type where the warning lamp fails to turn on
when it should, or remains on when it should not.
The warning lamp bulb is supplied a 12 volt igni-
tion feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit
Fig. 14 Master Cylinder For Antilock Brake
Equipped Vehicles
Fig. 15 Non-ABS Master Cylinder Primary And
Secondary Ports
Fig. 16 Power Brake Booster Identification
PLBRAKES 5 - 7
DESCRIPTION AND OPERATION (Continued)

FRONT DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the brake rotor and caliper should be
done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, it should be
replaced immediately.
During removal and installation of a wheel and
tire, use care not to strike the caliper.
NOTE: Before vehicle is moved after any brake
service work, pump the brake pedal several times
to insure the vehicle has a firm brake pedal.
NOTE: Starting with the 1998 model year, different
lining material is used on the disc brake shoes
depending on the type of brake system the vehicle
is equipped with. Vehicles equipped with standard
front disc and rear drum brakes use a new lining
material on the front disc brake shoes. Vehicles that
are equipped with optional 4 wheel disc brakes use
a new lining material on both the front and rear disc
brake shoes. When new brake shoes are installed,be sure brake shoes for the correct model year and
type of brake system the vehicle is equipped with
are used.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove the front wheel and tire assemblies
from vehicle.
(3) Remove the 2 guide pin bolts (Fig. 60) mount-
ing the caliper to the steering knuckle.
(4) Remove brake caliper from steering knuckle, by
first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
61).
(5) Support caliper firmly to prevent weight of cal-
iper from damaging the flexible brake hose (Fig. 62).
Fig. 60 Caliper Guide Pin Bolts
Fig. 61 Removing Caliper From Steering Knuckle
5 - 28 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Carefully lower caliper and brake shoe assem-
blies over braking disc (rotor) reversing the required
removal procedure (Fig. 71). Make sure that the cal-
iper guide pin bolts, bushings and sleeves are clear of
the adapter bosses.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(5) Install caliper assembly guide pin bolts into
adapter and tighten (Fig. 70). Then torque both guide
pin bolts to 22 N´m (192 in. lbs.).
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(8) Remove jackstands or lower hoist.Before
moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake
pedal.
(9) Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake pads.
REAR DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.During service procedures, grease or any other for-
eign material must be kept off caliper assembly, sur-
faces of braking rotor and external surfaces of hub.
Handling of the braking rotor and caliper should
be done in such a way as to avoid deformation of the
rotor and scratching or nicking of the brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, it should be
replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
NOTE: Before vehicle is moved after any brake
service work, pump the brake pedal several times
to insure the vehicle has a firm brake pedal.
NOTE: Starting with the 1998 model year, different
lining material is used on the rear disc brake shoes.
Vehicles equipped with optional 4 wheel disc
brakes use a new lining material on the rear disc
brake shoes than prior model year vehicles
equipped with this brake system. When new brake
shoes are installed, be sure brake shoes for the
correct model year and type of brake system the
vehicle is equipped with are used.REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the 2 caliper assembly to adapter
guide pin bolts (Fig. 74).
(4) Remove caliper assembly from adapter and
rotor by first rotating top of caliper assembly away
Fig. 74 Caliper Assembly Guide Pin Bolts
5 - 32 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

MASTER CYLINDER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, be sure engine is
not running, and pump the brake pedal until a firm
pedal is achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector, from
brake fluid level sensor, in master cylinder brake
fluid reservoir (Fig. 103).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 104) and (Fig.
105). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner product such as Mopar Brake
Parts Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 106) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 107) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 107) located in the front of the power
brake vacuum booster. Vacuum seal is removed by
Fig. 102 Caliper Guide Pin Bolts
Fig. 103 Master Cylinder Fluid Level Sensor
Fig. 104 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 105 Primary And Secondary Brake Tubes With
ABS Brakes
PLBRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)

carefullyinserting a small screw driver between the
push rod of the power brake vacuum booster and vac-
uum seal (Fig. 107) 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.
BLEEDING MASTER CYLINDER
(1) Clamp the master cylinder in a vise. Attach
Bleeding Tubes, Special Tool 6802 to the master cyl-
inder (Fig. 108) and (Fig. 109). Position tubes so out-
lets of Bleeding Tubes will be below surface of brake
fluid when reservoir is filled to proper level.
(2) Fill brake fluid reservoir with brake fluid con-
forming to DOT 3 specifications such as Mopar or an
Equivalent.
(3) Using a wooden dowel per (Fig. 110), depress
push rod slowly and then allow pistons to return to
released position. Repeat several times until all air
bubbles are expelled.
Fig. 106 Master Cylinder Mounting To Vacuum
Booster
Fig. 107 Removing Seal From Vacuum Booster
Fig. 108 Bleeding Tubes Attached to ABS Master
Cylinder
Fig. 109 Bleeding Tubes Attached To Non-ABS
Master Cylinder
Fig. 110 Bleeding Master Cylinder
5 - 42 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

(4) Remove bleeding tubes from master cylinder
outlet ports, plug outlet ports and install fill cap on
reservoir.
(5) Remove master cylinder from vise.
NOTE: Note: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der. But the master cylinder must have been bled
and filled upon installation.
INSTALL
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.
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.
(1) Lubricate master cylinder push rod as indi-
cated in (Fig. 111) only usingMopar Dielectric
GreaseÐAnd No Substitutes.Refer to the Mopar
Chemicals Catalog to obtain the required lubricant.
(2) Install vacuum seal on master cylinder push
rod as shown in (Fig. 112) 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. 113)
before installing master cylinder on power brake vac-
uum booster.CAUTION: If vehicle is equipped with ABS, be sure
old vacuum seal is removed from power brake vac-
uum booster before attempting to install master cyl-
inder and NEW vacuum seal. If vacuum seal is not
removed, refer to Master Cylinder Removal in this
section of the service manual for required vacuum
seal removal procedure.
(3) Position master cylinder on studs of power
brake unit, aligning push rod on power brake vac-
uum booster with master cylinder push rod.
(4) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 106) and torque to 28 N´m
(250 in. lbs.) torque.
(5) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 104) and (Fig. 105).
Torque all tube nuts to 17 N´m (145 in. lbs.) torque.
Fig. 111 Lubricating Master Cylinder Push Rod
Fig. 112 Installing Vacuum Seal On Master Cylinder
Push Rod
Fig. 113 Vacuum Seal Positioned For Installing
Master Cinder
PLBRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

VACUUM BOOSTER
REMOVE
CAUTION: On ABS equipped vehicles, vacuum in
power booster must be pumped down before
removing master cylinder to prevent booster from
sucking in any contamination. This can be done
simply by pumping the brake pedal until a firm
pedal is achieved, with the ignition off.
(1) On ABS equipped vehicles, with engine not
running, pump the brake pedal until a firm pedal is
achieved (4-5 strokes).
(2) Remove vehicle wiring harness connector from
brake fluid level sensor located in master cylinder
brake fluid reservoir (Fig. 114).
(3) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 115) and (Fig.
116). Install plugs at all open brake tube outlets on
master cylinder assembly.(4) On vehicles equipped with ABS, clean area
where master cylinder attaches to booster using a
suitable brake cleaner such as Mopar Brake Parts
Cleaner or an equivalent.
(5) Remove the 2 nuts (Fig. 117) attaching master
cylinder housing to power brake vacuum booster.
(6) Slide master cylinder assembly straight out of
the power brake vacuum booster.
CAUTION: On vehicles equipped with ABS, the
master cylinder is used to create the seal for hold-
ing vacuum in the power brake vacuum booster.
The vacuum seal in the front of the power brake
vacuum booster (Fig. 118) MUST be replaced when-
ever the master cylinder is removed from the power
brake vacuum booster.
(7) If vehicle is equipped with ABS, remove vac-
uum seal (Fig. 118) located in the front of the power
Fig. 114 Master Cylinder Fluid Level Sensor
Fig. 115 Primary And Secondary Brake Tubes W/O
ABS Brakes
Fig. 116 Primary And Secondary Brake Tubes With
ABS Brakes
Fig. 117 Master Cylinder Mounting To Vacuum
Booster
5 - 44 BRAKESPL
REMOVAL AND INSTALLATION (Continued)