Master Cylinder Reservoir Replacement
Brake Fluid ReservoirRemove
1. Thoroughly clean the master cylinder and the brake fluid reservoir.
2. Remove the master cylinder from the vacuum booster. Refer to Master Cylinder, Brakes, Service and Repair, Removal And Installation for the procedure.
3. Using a syringe or other equivalent tool, empty as much brake fluid as possible from the brake fluid reservoir.
Caution: When mounting master cylinder in vise, clamp the master cylinder only by the mounting flange. Do not clamp on primary piston, seal or body of master cylinder.
Correctly Mounted Master Cylinder:
4. Mount master cylinder in a vise.
Remove/Replace Reservoir Mounting Pins:
5. Using a pin punch, remove the 2 roll pins retaining brake fluid reservoir to master cylinder.
Caution: When removing the fluid reservoir from the master cylinder do not pry the reservoir off with a tool, damage to fluid reservoir may result.
Removing Fluid Reservoir:
6. Rock brake fluid reservoir from side to side while pulling upward to remove it from sealing grommets in master cylinder.
Caution: The brake fluid reservoir to master cylinder sealing grommets can not be reused. Discard the sealing grommets after removing them from the master cylinder.
Remove Seal Grommets:
7. Remove master cylinder-to-fluid reservoir sealing grommets from master cylinder.
Install
1. Lubricate the NEW brake fluid reservoir to master cylinder seal grommets with fresh clean brake fluid.
Installing Seal Grommets:
2. Install new seal grommets in the master cylinder.
3. Lubricate the fluid ports on the brake fluid reservoir with clean fresh brake fluid.
Installing Brake Fluid Reservoir:
4. Place fluid reservoir in correct position over seal grommets. Seat fluid reservoir into seal grommets/master cylinder using a rocking motion while firmly pushing down on fluid reservoir.
Fluid Reservoir Installed On Master Cylinder:
5. Make sure brake fluid reservoir is installed on master cylinder until bottom of reservoir touches the top of both seal grommets.
6. Using a pin punch install the 2 roll pins retaining the brake fluid reservoir to the master cylinder.
7. Bleed the master cylinder prior to mounting it on the vacuum booster.
Bleeding Master Cylinder
Note: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder fluid reservoir, providing that the master cylinder has been filled and bled prior to installation.
1. Attach Bleeding Tubes, Special Tool 8129 to the master cylinder. Position bleeding tubes so outlets will be below the surface of the brake fluid when the fluid reservoir is filled to the proper level.
2. Fill the fluid reservoir to the proper level with brake fluid conforming to DOT 3 specifications such as Mopar or Equivalent.
3. Using a wooden dowel, slowly depress the piston of the master cylinder until it has bottomed in the master cylinder then allow the piston to return to the released position. Repeat this step several times until no more air bubbles are expelled from the bleeding tubes.
4. Remove the bleeding tubes from the master cylinder.
5. Plug the output ports of the master cylinder and install the cap on the fluid reservoir.
6. Install the master cylinder on the vacuum booster. Refer to Removal And Installation for the procedure.