Chrysler Stratus Convertible. Manual — part 191

CAUTION: When installing the retaining clip on the
brake pedal pin a NEW retaining clip must be used
to ensure the retention of the vacuum booster push
rod.

(7) Install a new retaining clip (Fig. 50) on the

brake pedal pin.

(8) Using Mopar Lubriplate or an equivalent,

lightly lubricate the surface of the brake pedal
striker where the plunger of the brake lamp switch
contacts it.

NOTE: Prior to installing the brake lamp switch into
its bracket, the plunger must be moved to its fully
extended position using the procedure in Step 9.

(9) Hold stop lamp switch firmly in one hand.

Using other hand, pull outward on the plunger of the
stop lamp switch until it has ratcheted out to its
fully extended position.

(10) Install the brake lamp switch in the brake

pedal bracket (Fig. 49). Install it using the following
procedure. Depress the brake pedal as far down as
possible. Then while holding brake pedal down, align
the index key on switch with slot in square hole of
mounting bracket. When switch is fully installed into
the bracket, rotate stop lamp switch in a clockwise
direction approximately 30 degrees until it is aligned
straight up and down (Fig. 51).

CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the brake lamp
switch. If to much force is used, damage to the
brake lamp switch or striker can result.

(11) Gently release/pull back the brake pedal until

it stops moving. This will cause the switch plunger to
ratchet back to its correctly adjusted position.

(12) Install the heat distribution duct.
(13) Install the two screws securing the bottom of

the knee bolster below the steering column in place
(Fig. 48).

(14) Connect the remote ground cable for the bat-

tery on the ground post located on left shock tower
(Fig. 46).

MASTER CYLINDER

REMOVE

(1) Remove wiring harness connector from brake

fluid level sensor in master cylinder brake fluid res-
ervoir (Fig. 52).

(2) Disconnect the primary and secondary brake

tubes from the master cylinder outlet ports (Fig. 53)
(Fig. 54). Install plugs at all open brake tube outlets
on master cylinder assembly.

(3) Using Mopar, Brake Parts Cleaner or an equiv-

alent, clean the area where the master cylinder
attaches to the vacuum booster.

(4) Remove the 2 nuts (Fig. 55) attaching the mas-

ter cylinder to the vacuum booster.

CAUTION: When removing the routing clip and
brake tubes from the mounting stud, do not bend or
kink the chassis brake line tubes.

(5) Remove the routing clip and chassis brake

tubes (Fig. 55)(as an assembly) from the mounting
stud for the master cylinder.

Fig. 51 Brake Lamp Switch

1 – SWITCH
2 – ACCELERATOR PEDAL
3 – BRAKE PEDAL
4 – STEERING COLUMN INTERMEDIATE SHAFT

Fig. 52 Master Cylinder Fluid Level Sensor

1 – BRAKE FLUID RESERVOIR
2 – BRAKE FLUID LEVEL SENSOR
3 – WIRING HARNESS CONNECTOR
4 – MASTER CYLINDER

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BRAKES

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REMOVAL AND INSTALLATION (Continued)

(6) Slide the master cylinder straight off its

mounting studs on the vacuum booster.

BLEEDING MASTER CYLINDER

(1) Clamp the master cylinder in a vise. Attach

Bleeding Tubes, Special Tool 6802 to the master cyl-
inder outlet ports (Fig. 56) (Fig. 57). Position the
bleeding tubes so outlets of the tubes will be
below the surface of the brake fluid when res-
ervoir is filled to the proper level.

(2) Fill brake fluid reservoir with brake fluid con-

forming to DOT 3 specifications such as Mopar or an
Equivalent.

(3) Insert an appropriate size wooden dowel in the

end of the master cylinder piston (Fig. 58). Using the
dowel, slowly depress the piston to the full extent of
its travel and then allow the piston to return to its
released position. Continue to repeat this step until
bubbles no longer appear in the brake fluid. After no
more air bubbles are expelled from the bleed tubes
repeat the above procedure several more times to
ensure all air is bled from master cylinder.

Fig. 53 Master Cylinder Primary And Secondary

Ports With ABS

1 – MASTER CYLINDER ASSEMBLY
2 – BRAKE FLUID RESERVOIR
3 – MASTER CYLINDER PRIMARY PORT
4 – MASTER CYLINDER SECONDARY PORT

Fig. 54 Master Cylinder Primary And Secondary

Ports Without ABS

1 – MASTER CYLINDER PRIMARY PORTS
2 – MASTER CYLINDER
3 – MASTER CYLINDER SECONDARY PORTS
4 – MASTER CYLINDER FLUID RESERVOIR

Fig. 55 Master Cylinder Mounting To Vacuum

Booster

1 – BRAKE VACUUM BOOSTER
2 – BRAKE FLUID RESERVOIR
3 – MASTER CYLINDER
4 – MOUNTING NUTS
5 – ROUTING CLIP

Fig. 56 Bleeding Tubes Attached to ABS Master

Cylinder

1 – MASTER CYLINDER FLUID RESERVOIR
2 – MASTER CYLINDER
3 – SPECIAL TOOL 8129

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REMOVAL AND INSTALLATION (Continued)

(4) Remove the bleeding tubes from the outlet

ports of the master cylinder.

(5) Plug outlet ports of master cylinder and install

the cap on the reservoir.

(6) Remove the master cylinder from the vise.

NOTE: Note: It is not necessary to bleed the entire
hydraulic system after replacing the master cylin-
der. However, the master cylinder must have been
bled and filled upon installation.

INSTALL

(1) Position master cylinder assembly on studs of

power brake unit, aligning push rod on power brake
vacuum booster with piston of master cylinder.

CAUTION: When installing the routing clip and
brake tubes on the mounting stud, do not bend or
kink the chassis brake line tubes. Be sure the chas-
sis brake tubes are routed correctly. The chassis
brake tubes can not touch each other or other com-
ponents or the body of the vehicle.

(2) Install the routing clip and chassis brake tubes

(Fig. 55) on the inboard mounting stud for the mas-
ter cylinder.

(3) Install the 2 master cylinder to power brake

vacuum booster mounting nuts (Fig. 55). Tighten
both nuts to a torque of 28 N·m (250 in. lbs.).

(4) Connect brake tubes to master cylinder pri-

mary and secondary ports (Fig. 53). Then tighten the
tube nuts to a torque of 17 N·m (145 in. lbs.).

(5) Install the connector from the vehicle wiring

harness on the fluid level sensor in the master cylin-
der fluid reservoir (Fig. 52)

BRAKE FLUID LEVEL SWITCH

The master cylinder or brake fluid reservoir does

not have to be removed from the vehicle for replace-
ment of the brake fluid level sensor.

(1) Remove wiring harness connector from brake

fluid reservoir level sensor (Fig. 59).

Fig. 57 Bleeding Tubes Attached to Non-ABS Master

Cylinder

1 – MASTER CYLINDER ASSEMBLY
2 – SPECIAL TOOL 6802

Fig. 58 Bleeding Master Cylinder

1 – BRAKE FLUID RESERVOIR
2 – MASTER CYLINDER
3 – WOODEN DOWEL
4 – SPECIAL TOOL 8129

Fig. 59 Master Cylinder Fluid Level Sensor

1 – BRAKE FLUID RESERVOIR
2 – BRAKE FLUID LEVEL SENSOR
3 – WIRING HARNESS CONNECTOR
4 – MASTER CYLINDER

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REMOVAL AND INSTALLATION (Continued)

(2) Compress the retaining tabs (Fig. 60) on the

end of the brake fluid level sensor.

(3) While compressing retaining tabs, grasp oppo-

site end of brake fluid level sensor and pull it out of
master cylinder fluid reservoir (Fig. 61).

POWER BRAKE BOOSTER (2.5L ENGINE)

REMOVAL

(1) Remove the remote ground cable from the

ground stud located on the left shock tower (Fig. 62).

(2) Correctly isolate remote ground cable when ser-

vicing vehicle by installing the ground cable insulator
on the strut tower ground stud as shown (Fig. 63).
This will prevent accidental grounding of the
remote ground cable.

Fig. 60 Brake Fluid Level Switch Retaining Tabs

1 – MASTER CYLINDER BRAKE FLUID RESERVOIR
2 – MASTER CYLINDER
3 – FLUID LEVEL SWITCH RETAINING TABS

Fig. 61 Removing Fluid Level Switch From

Reservoir

1 – MASTER CYLINDER BRAKE FLUID RESERVOIR
2 – BRAKE FLUID LEVEL SWITCH
3 – MASTER CYLINDER

Fig. 62 Ground Cable Attachment To Strut Tower

1 – SPEED CONTROL SERVO
2 – LEFT STRUT TOWER
3 – GROUND STUD
4 – AIR CLEANER
5 – REMOTE GROUND CABLE
6 – MASTER CYLINDER

Fig. 63 Correctly Isolated Remote Ground Cable

1 – LEFT STRUT TOWER
2 – GROUND STUD

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REMOVAL AND INSTALLATION (Continued)