Chrysler Pacifica. Manual — part 453
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
(4) Using a wooden dowel as a pushrod (Fig. 47),
slowly depress master cylinder pistons, then release
pressure, allowing pistons to return to released posi-
tion. Repeat several times until all air bubbles are
expelled. Make sure fluid level stays above tips of
bleeder tubes in reservoir while bleeding.
(5) Remove bleeder tubes from master cylinder
outlet ports, then plug outlet ports and install fill cap
on reservoir.
(6) Remove master cylinder from vise.
(7) Install master cylinder on vehicle. (Refer to 5 -
BRAKES - BASE/HYDRAULIC/MECHANICAL/MAS-
TER CYLINDER - INSTALLATION)
REMOVAL
CAUTION: Vacuum in power brake booster must be
pumped down (removed) before removing master
cylinder from power brake booster. This is neces-
sary 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.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4-5 strokes).
(2) Disconnect negative battery cable from battery
post and isolate.
(3) Thoroughly clean all surfaces of brake fluid
reservoir and master cylinder. Use only Mopar
t
Brake Parts Cleaner or equivalent.
(4) Disconnect
wiring
harness
connector
from
brake fluid level switch in master cylinder brake
fluid reservoir (Fig. 48).
(5) Disconnect primary and secondary brake tubes
from master cylinder (Fig. 49). Install sealing plugs
in open brake tube outlet ports.
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.
(6) Clean area where master cylinder assembly
attaches to power brake booster. Use only Mopar
t
Brake Parts Cleaner or equivalent.
(7) Remove two nuts attaching master cylinder to
power brake booster (Fig. 49).
(8) 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.
(9) Remove vacuum seal located on mounting
flange of master cylinder. Vacuum seal is removed
Fig. 48 Brake Fluid Level Switch Connector
1 - MASTER CYLINDER RESERVOIR
2 - WIRING CONNECTOR
3 - ABS ICU
4 - BRAKE FLUID LEVEL SWITCH
Fig. 49 Master Cylinder Mounting
1 - ENGINE INTAKE MANIFOLD
2 - BOOSTER VACUUM HOSE
3 - POWER BRAKE BOOSTER
4 - MASTER CYLINDER
5 - PRIMARY BRAKE TUBE
6 - SECONDARY BRAKE TUBE
7 - ABS ICU
8 - MASTER CYLINDER MOUNTING NUT (2)
CS
BRAKES - BASE
5 - 27
MASTER CYLINDER (Continued)
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.
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Clean master cylinder housing and brake fluid
reservoir. Use only a solvent such as Mopar Brake
Parts Cleaner or an equivalent.
(2) Remove brake fluid reservoir cap. Using a
syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cylinder assembly from the
power brake vacuum booster. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER
CYL-
INDER - REMOVAL).
(4) Mount the master cylinder in a vise using the
master cylinder mounting flange.
(5) Using correct size pin punch, remove the two
retaining pins between the fluid reservoir and master
cylinder housing (Fig. 50).
(6) Rock the brake fluid reservoir from side to side
while pulling up to remove it from the seal grommets
in master cylinder housing.
(7) Remove the two master cylinder housing to
brake fluid reservoir seal grommets (Fig. 51).
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Install new master cylinder housing to brake
fluid reservoir sealing grommets in master cylinder
housing (Fig. 51).
(2) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir.
(3) Be sure fluid reservoir is positioned properly on
master cylinder. Bottom of fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.
(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 50).
(5) Install the master cylinder assembly on the
power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
INSTALLATION)
(6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION
(1) Thoroughly
bleed
master
cylinder
before
installing it on vehicle. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
STANDARD PROCEDURE)
CAUTION: When replacing master cylinder on vehi-
cle, a NEW vacuum seal MUST be installed on mas-
ter cylinder.
Fig. 50 Fluid Reservoir Retaining Pins (Typical)
1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER
Fig. 51 Master Cylinder To Fluid Reservoir Seal
Grommets
1 - SEAL GROMMETS
2 - MASTER CYLINDER
5 - 28
BRAKES - BASE
CS
MASTER CYLINDER (Continued)
(2) Install NEW vacuum seal on rear of master
cylinder making sure seal fits squarely in mounting
groove.
(3) Position master cylinder on studs of power
brake booster (Fig. 49), aligning booster push rod
with master cylinder piston.
(4) Install two master cylinder mounting nuts (Fig.
49). Tighten both mounting nuts to a torque of 25
N·m (225 in. lbs.).
CAUTION: When tightening primary and secondary
brake tube nuts at master cylinder, be sure brake
tubes do not contact any other components within
vehicle and that there is slack in flexible sections of
tubes. This is required due to movement between
ABS ICU and master cylinder while vehicle is in
motion.
(5) Thread primary and secondary brake tubes
into master cylinder primary and secondary ports
(Fig. 49). Brake tubes must be held securely when
tightened to control orientation of flex section.
Tighten tube nuts to 14 N·m (120 in. lbs.) torque.
(6) Connect wiring harness connector to brake
fluid level switch mounted in brake fluid reservoir
(Fig. 48).
(7) Connect negative battery cable to battery post.
(8) Fill master cylinder with clean, fresh Mopar
t
Brake Fluid or equivalent.
WARNING: BE CERTAIN A FIRM BRAKE PEDAL IS
ACHIEVED
PRIOR
TO
ATTEMPTING
VEHICLE
OPERATION. IF A FIRM BRAKE PEDAL CANNOT BE
ACHIEVED, BLEED ENTIRE BRAKE HYDRAULIC
SYSTEM AND CHECK FOR LEAKS. (Refer to 5 -
BRAKES - STANDARD PROCEDURE)
(9) Road test vehicle to ensure proper operation of
brakes.
PEDALS - ADJUSTABLE
REMOVAL
(1) Move driver’s seat to full rearward position.
(2) Disconnect negative battery cable from battery
post and isolate.
(3) Remove engine appearance cover.
(4) Remove throttle cable from throttle body lever.
(5) Access and remove knee blocker airbag. (Refer
to
8
-
ELECTRICAL/RESTRAINTS/KNEE
BLOCKER AIRBAG - REMOVAL)
(6) Place front wheels and steering wheel in the
STRAIGHT-AHEAD position. Lock steering wheel in
place using steering wheel holder (Fig. 52).
(7) Disconnect steering column coupling at inter-
mediate shaft. To do so:
(a) Remove hair pin at end of coupling pinch
bolt.
(b) Loosen nut and remove pinch bolt.
(c) Remove intermediate shaft from coupling.
(8) Remove four screws securing instrument panel
lower left reinforcement. Remove reinforcement.
(9) Remove booster push rod from pin on brake
pedal (Fig. 53). To do so:
(a) Position small screwdriver between center
tang on power brake booster brake pedal pin
retaining clip.
(b) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal
pin, then slide retaining clip off brake pedal pin.
(c) Discard retaining clip. It is not to be
reused.
Install
NEW
retaining
clip
when
assembling.
(10) Slide booster push rod off brake pedal pin.
(11) Remove clip disconnecting throttle cable from
accelerator pedal.
(12) Remove and discard brake lamp switch. Do
not reuse switch; install NEW switch on Instal-
lation. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING
-
EXTERIOR/BRAKE
LAMP
SWITCH
-
REMOVAL)
(13) Disconnect wiring connectors at brake pedal
position sensor and adjustable pedal motor.
(14) Remove four power brake booster mounting
nuts (Fig. 53).
(15) Remove two nuts fastening pedal bracket to
upper dash panel bracket.
(16) Remove adjustable pedals assembly.
Fig. 52 Steering Wheel Holder
CS
BRAKES - BASE
5 - 29
MASTER CYLINDER (Continued)
INSTALLATION
(1) Install
adjustable
pedals
assembly
under
instrument panel and slide onto power brake booster
studs.
(2) Install two nuts fastening pedal bracket to
upper dash panel bracket (Fig. 53). Tighten nuts to
28 N·m (21 ft. lbs.) torque.
(3) Install four power brake booster mounting nuts
(Fig. 53). Tighten nuts to 28 N·m (21 ft. lbs.) torque.
(4) Connect wiring connectors at brake pedal posi-
tion sensor and adjustable pedal motor.
(5) Install clip connecting throttle cable to acceler-
ator pedal.
(6) Slide booster push rod onto brake pedal pin
(Fig. 53). Install NEW retaining clip securing push
rod to brake pedal.
(7) Install and adjust NEW brake lamp switch
(Fig. 53). (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING
-
EXTERIOR/BRAKE
LAMP
SWITCH
-
INSTALLATION)
(8) Connect steering column coupling to intermedi-
ate shaft. To do so:
(a) Match intermediate shaft to coupling pinch
loop.
(b) Install coupling pinch bolt. Tighten to 28
N·m (21 ft. lbs.) torque.
(c) Install hair pin at end of pinch bolt.
(9) Install instrument panel lower left reinforce-
ment.
(10) Remove steering wheel holder.
(11) Install knee blocker airbag as well as all com-
ponents necessary to access it. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/KNEE BLOCKER AIRBAG -
INSTALLATION)
(12) Install throttle cable onto throttle body lever.
(13) Install engine appearance cover.
(14) Connect negative battery cable to battery
post.
(15) Test operation of adjustable pedals.
(16) Road test vehicle testing operation of steering,
brakes and accelerator.
POWER BRAKE BOOSTER
REMOVAL
(1) Move driver’s seat to full rearward position.
(2) Disconnect negative (-) battery cable from bat-
tery post and isolate.
(3) Remove battery from vehicle. (Refer to 8 -
ELECTRICAL/BATTERY
SYSTEM/BATTERY
-
REMOVAL)
Fig. 53 Adjustable Pedals And Booster Mounting
1 - BRAKE LAMP SWITCH
2 - DASH PANEL BRACKET
3 - PEDAL MOUNTING STUDS
4 - POWER BRAKE BOOSTER
5 - RETAINING CLIP
6 - BOOSTER PUSH ROD
7 - BOOSTER MOUNTING NUT
8 - BOOSTER MOUNTING STUDS
9 - PEDAL BRACKET MOUNTING NUT
10 - ADJUSTABLE PEDALS ASSEMBLY
11 - BRAKE LAMP SWITCH MOUNT
5 - 30
BRAKES - BASE
CS
PEDALS - ADJUSTABLE (Continued)
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