Master Cylinder Replacement
CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with traction control use a center port master cylinder. Vehicles not equipped with traction control use a compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four wheel disc brakes have a master with a different size piston bore than the other master cylinders. If a new master cylinder is being installed, be sure the correct master cylinder is used for the type of brake system the vehicle is equipped with.REMOVE
CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved.
1. With engine not running, pump the brake pedal until a firm pedal is achieved (4 - 5 strokes).
CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the brake fluid reservoir and entering the brakes hydraulic system.
2. Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent.
Master Cylinder Filler Tube Removal:

3. Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating. Then remove the cap from the removed filler tube and install it on the master cylinder reservoir.
Master Cylinder Assembly:

4. Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder brake fluid reservoir.
Primary/Secondary Brake Tubes At Master Cylinder:

5. Disconnect the primary and secondary brake tubes from the master cylinder housing. Install sealing plugs in the open brake tube outlets on master cylinder assembly.
CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the power brake vacuum booster.
6. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent.
Master Cylinder Mounting To Vacuum Booster:

7. Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster.
8. Slide master cylinder assembly straight out of the power brake vacuum booster.
CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal/boot on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster.
9. Remove the vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from the master cylinder by carefully pulling it away from the master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting.
NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the hydraulic system when the master cylinder was removed.
INSTALL
CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal onto the master cylinder.
Vacuum Seal Installed On Master Cylinder:

1. Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of master cylinder casting.
2. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod.
3. Install the 2 master cylinder to power brake unit mounting nuts. Then tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.).
CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS hydraulic control module HCU and the master cylinder, when the vehicle is in motion.
4. Connect the primary and secondary brake tubes to master cylinder primary and secondary ports. Brake tubes must be held securely when tightened to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 inch lbs.).
5. Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder brake fluid reservoir.
6. Install filler tube into the master cylinder fluid reservoir.