- Disconnect negative (-) battery cable from battery post and isolate.
CAUTION:
Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent power brake booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping brake pedal, with vehicle's engine not running, until a firm feeling brake pedal is achieved.
- With engine, not running, pump brake pedal until a firm pedal is achieved (4-5 strokes).
- Remove nuts fastening coolant recovery bottle in place and reposition bottle with hoses attached out of way. (Refer to COOLANT RECOVERY PRESS CONTAINER
).
CAUTION:
Before removing master cylinder from power brake vacuum booster, master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into power brake vacuum booster.
- Thoroughly clean all surfaces of brake fluid reservoir and master cylinder, paying special attention to area where master cylinder attaches to power brake booster. Use only Mopar(R) Brake Parts Cleaner or equivalent.
- Disconnect wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig 1
).
Courtesy of DAIMLERCHRYSLER CORP.
- Disconnect primary and secondary brake tubes coming from master cylinder at ABS ICU (Fig 2
). Cap off brake tubes and install sealing plugs in open brake tube outlet ports of ICU.
Courtesy of DAIMLERCHRYSLER CORP.
- Remove two nuts attaching master cylinder to power brake booster (Fig 3
).
- Slide master cylinder straight out of power brake booster.
CAUTION:
Seal on rear of master cylinder is used to create seal for holding vacuum in power brake vacuum booster. Vacuum seal on master cylinder MUST be replaced whenever master cylinder is removed from power brake vacuum booster.
- Remove vacuum seal located on mounting flange of master cylinder. Vacuum seal is removed from master cylinder by carefully
pulling it off rear of master cylinder. Do not attempt to pry seal off master cylinder by inserting a sharp tool between seal and master cylinder casting.
- Disconnect four chassis brake tubes at ABS ICU (Fig 4
). Cap off brake tubes and install sealing plugs in open brake tube outlet ports of ICU.
Courtesy of DAIMLERCHRYSLER CORP.
Courtesy of DAIMLERCHRYSLER CORP.
- Disconnect 47-way wiring connector at CAB (Fig 5
).
- Loosen 2 bolts fastening ABS ICU bracket to frame rail (Fig 5
).
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- Lift ICU off frame rail bolts and remove from vehicle.
- If CAB and HCU need to be separated, (Refer to DISASSEMBLY
).