Chrysler 300M, Dodge Interpid. Manual — part 36
NOTE: The master cylinder outlet ports use ISO
style flares and metric threads. Special Tool Pack-
age 8822 includes ISO style flare adapters with met-
ric threads to be used in conjunction with Bleeder
Tubes, Special Tool Package 8358.
(2) Attach special tools for bleeding master cylin-
der in the following fashion:
(a) For non-ABS master cylinders, thread one
Adapter, Special Tool 8822–2, into each outlet port.
Tighten Adapters to 17 N·m (145 in. lbs.) torque.
(b) For ABS master cylinders, thread one
Adapter, Special Tools 8822–2, into the primary
outlet port and one Adapter, Special Tool 8822–1,
into the secondary outlet port. Tighten Adapters to
17 N·m (145 in. lbs.) torque.
(c) Thread
one
Bleeder
Tube,
Special
Tool
8358–1, into each Adapter. Tighten each tube to 17
N·m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 65).
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level to avoid ingesting air while bleeding.
(3) Fill reservoir with Mopar
t Brake Fluid or
equivalent conforming to DOT 3 specifications. Make
sure fluid level is above tips of bleeder tubes in res-
ervoir.
(4) Using a wooden dowel as a pushrod (Fig. 65),
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 bleeding tubes. Plug outlets and install
filler cap.
(6) Remove master cylinder from vise and install
on power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
INSTALLATION)
REMOVAL
(1) Disconnect brake fluid level switch wire con-
nector on the side of the master cylinder reservoir.
(2) Disconnect primary and secondary brake tubes
from master cylinder housing. Install plugs at brake
tube outlets.
(3) Remove the 2 nuts attaching the master cylin-
der to the power brake vacuum booster (Fig. 66).
(4) Slide master cylinder straight out from the
booster.
Fig. 65 Master Cylinder Set Up For Bleeding
1 - BLEEDER TUBES 8358
2 - NON-ABS - ADAPTER 8822-1; ABS - ADAPTER 8822-2
3 - ADAPTER 8822-2
4 - WOODEN DOWEL
Fig. 66 Master Cylinder Mounting
1 - MASTER CYLINDER MOUNTING NUTS
2 - POWER BRAKE BOOSTER
3 - MASTER CYLINDER
LH
BRAKES - BASE BRAKE SYSTEM
5 - 39
MASTER CYLINDER (Continued)
DISASSEMBLY
(1) Remove the master cylinder from the power
brake booster. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - REMOVAL)
(2) Using an appropriate cleaner such as Mopar
t
Brake Parts Cleaner, clean the master cylinder hous-
ing and brake fluid reservoir.
(3) Remove the filler cap and empty all brake fluid
from reservoir.
(4) Clamp the master cylinder in vise.
(5) Remove the 2 fluid reservoir to master cylinder
retaining pins (Fig. 67).
NOTE: Do not pry off fluid reservoir using a tool,
damage to reservoir may result.
(6) Remove reservoir from master cylinder by pull-
ing upward on the reservoir while rock it from side-
to-side (Fig. 68).
(7) Remove the master cylinder housing-to-reser-
voir grommets (Fig. 69).
(8) For reassembly, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
ASSEMBLY).
ASSEMBLY
(1) Install new housing-to-reservoir grommets in
master cylinder housing (Fig. 69).
(2) Lubricate
brake
fluid
reservoir-to-grommet
mounting area with clean brake fluid. Place reservoir
in position over grommets. Seat reservoir into sealing
grommets using a rocking motion while pushing
down on reservoir.
(3) Make sure bottom of reservoir touches the top
of both sealing grommets.
(4) Install the 2 fluid reservoir to master cylinder
retaining pins (Fig. 67).
(5) Bleed and install master cylinder on vehicle.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
MASTER CYLINDER - STANDARD PROCEDURE)
INSTALLATION
CAUTION: If the master cylinder is being replaced
or has been repaired, the master cylinder must be
bled before installation. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
STANDARD PROCEDURE)
(1) Install master cylinder on studs of power brake
vacuum booster, aligning the booster push rod with
master cylinder piston.
(2) Install the master cylinder mounting nuts (Fig.
66). Tighten the nuts to a torque of 28 N·m (250 in. lbs.).
(3) Connect brake tubes to master cylinder pri-
mary and secondary ports. Tighten fittings to 17 N·m
(145 in. lbs.) torque.
Fig. 67 Reservoir Retaining Pins
1 - BRAKE FLUID RESERVOIR
2 - DRIFT
3 - RETAINING PIN
4 - MASTER CYLINDER
Fig. 68 Removing Reservoir
1 - FLUID RESERVOIR
2 - MASTER CYLINDER
3 - SEALING GROMMETS
Fig. 69 Reservoir Sealing Grommets
1 - RESERVOIR SEALING GROMMETS
2 - MASTER CYLINDER
5 - 40
BRAKES - BASE BRAKE SYSTEM
LH
MASTER CYLINDER (Continued)
(4) Reconnect brake fluid level switch.
(5) Check and adjust brake fluid level as necessary
using Mopar
t Brake Fluid or equivalent.
CAUTION: It will be necessary to bleed the entire
base hydryaulic system if the brake system has
been open to air for an excessive amount of time or
air is present in the lines.
PEDAL
DESCRIPTION
A suspended type brake pedal is used on this vehi-
cle (Fig. 70). The pedal pivots on a shaft mounted in
the pedal support bracket under the instrument
panel. The pedal also connects to the power brake
booster input rod. The pedal ratio is 3.44:1.
OPERATION
When the brake pedal is depressed, it pushes in on
the power brake booster input rod applying the
brakes. At the same time, it allows the brake lamp
switch’s plunger to extend, thus applying the brake
lamps.
REMOVAL
(1) Disconnect and isolate the remote ground bat-
tery cable from the ground stud on the right strut
tower.
(2) Remove the brake lamp switch from its bracket
(Fig. 70). The brake lamp switch is removed by
depressing and holding the brake pedal while rotat-
ing brake lamp switch in a counterclockwise direction
approximately 30 degrees. Pull the switch rearward
and remove it from its mounting bracket.
(3) Remove the retaining clip from the brake pedal
pin securing the power brake booster to the pedal
using following procedure (Fig. 71). Position a small
screwdriver between the center tang on the retaining
clip and the brake pedal pin. Rotate blade of screw-
driver enough so center tang on retaining clip can
pass over end of brake pedal pin, then pull retaining
clip off brake pedal pin.
(4) Remove the booster input rod from the brake
pedal pin.
(5) Remove the nut from the brake pedal pivot
shaft (Fig. 70). The pivot shaft has a flat on it to hold
while the nut is removed.
(6) Remove the brake pedal pivot shaft from the
brake pedal and pedal mounting bracket.
(7) Remove the brake pedal with bushings from
mounting bracket (Fig. 70).
NOTE: The bushings can be easily removed from
the pedal by pulling them straight out each side.
INSTALLATION
(1) Make sure the pedal has a properly installed
bushing on each side of the pedal (Fig. 70).
(2) Lubricate the brake pedal pivot shaft and
brake pedal bushings using Mopar Lubriplate or an
equivalent.
(3) Install the brake pedal in the pedal bracket
(Fig. 70). Align the hole in brake pedal with the pivot
shaft holes in the pedal bracket.
(4) Install the brake pedal shaft (Fig. 70).
Fig. 70 Brake Pedal
1 - BUSHINGS
2 - BRAKE PEDAL
3 - BRAKE LAMP SWITCH
4 - PIVOT SHAFT
Fig. 71 Brake Pedal Retaining Clip
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
LH
BRAKES - BASE BRAKE SYSTEM
5 - 41
MASTER CYLINDER (Continued)
(5) Install the nut on the end of the brake pedal
pivot shaft. Tighten the nut to a torque of 34 N·m (25
ft. lbs.).
(6) Install the power brake booster input rod on
the brake pedal pin.
CAUTION: When installing the retaining clip on the
brake pedal pin, a NEW retaining clip must be used
to ensure the retention of the power brake booster
input rod.
(7) Install a new retaining clip (Fig. 71) 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 brake lamp switch firmly in one hand.
Using other hand, pull outward on the plunger of the
brake lamp switch until it has ratcheted out to its
fully extended position.
(10) Install the brake lamp switch in the brake
pedal bracket (Fig. 70). 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 notch in square hole of
mounting bracket. When the switch is fully installed
into the bracket, rotate the switch in a clockwise
direction approximately 30 degrees until it locks into
place.
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) Connect the remote ground cable to the
ground stud on the right front strut tower.
(13) Check the operation of the brakes and brake
lamp switch.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster assembly mounts on the
engine side of the dash panel. It is externally con-
nected to the brake pedal by an input push rod
extending out the rear of the booster (Fig. 72). The
master cylinder is bolted to the front of the power
brake booster assembly.
A vacuum check valve is mounted on the power
brake booster body. A vacuum line connects the
booster (check valve) to the intake manifold. Depend-
ing on the engine combination, different vacuum hose
routings are required.
Fig. 72 Power Brake Booster
1 - VACUUM CHECK VALVE
2 - OUTPUT ROD
3 - POWER BRAKE BOOSTER ASSEMBLY
4 - INPUT ROD
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - 42
BRAKES - BASE BRAKE SYSTEM
LH
PEDAL (Continued)
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