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Master Cylinder - RHD: Removal

Fig 1: Removing/Installing Air Cleaner Assembly
GC0022840Courtesy of DAIMLERCHRYSLER CORP.
1 - AIR CLEANER ASSEMBLY
  1. Remove air cleaner assembly (1). See Fig 1.
  2. Disconnect battery negative cable.
    CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
  3. Remove PDC bracket and position out of way.
    Fig 2: Hydraulic Tube Retainer Clips - Diesel/Turbo
    GC0022834Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINER CLIPS
  4. Disconnect hydraulic supply tube at clutch slave cylinder. To completely drain clutch master cylinder and tubing, remove brake master cylinder cap.
    • 1.6L/2.4L N/A Models:  Raise vehicle on hoist. Using suitable screwdriver, release both hydraulic tube retaining clips (1). See Fig 2. Disconnect tube and drain fluid into suitable container. Lower vehicle.
    • 2.4L Turbo & Diesel Models:  Using suitable screwdriver, release both hydraulic tube retaining clips. Disconnect tube and drain fluid into suitable container.
    Fig 3: Lower Instrument Panel Bezel
    G04241533Courtesy of DAIMLERCHRYSLER CORP.
  5. From inside vehicle, remove lower instrument panel bezel (2). See Fig 3.
    Fig 4: Brake Booster Mounting Nuts
    GC0019805Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLIP
    2 - BOOSTER MOUNTING NUTS
    3 - BOOSTER MOUNTING NUTS
  6. Remove clip and disconnect the brake booster input rod from the brake pedal pin. See Fig 4.
  7. Remove the brake booster mounting nuts. See Fig 4.
  8. Slide brake booster forward enough to gain access to and remove clutch master cylinder.
  9. Disconnect clutch master cylinder pushrod from clutch pedal. Inspect retainer bushing and replace if damaged in any way. 
    Fig 5: Clutch Master Cylinder Supply Hose
    GC0022832Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRAKE MASTER CYLINDER RESERVOIR
    2 - HOSE CLAMP
    3 - CLUTCH MASTER CYLINDER SUPPLY HOSE
  10. Disconnect clutch master cylinder supply line from brake master cylinder reservoir. See Fig 5. Cap off or collect reservoir fluid spillage.
    Fig 6: Master Cylinder Pipe At Left Rail
    GC0022841Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINER
    2 - MASTER CYLINDER PIPE
  11. Remove hydraulic tube from left rail retainer. See Fig 6.
    CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.
    Fig 7: Clutch Master Cylinder Mounting - RHD
    GC0022839Courtesy of DAIMLERCHRYSLER CORP.
    1 - RESERVOIR
  12. Disengage master cylinder grommet and slide back. See Fig 7.
  13. Release master cylinder by rotating to disengage from pedal bracket assembly. 1.6/2.4L models: Rotate master cylinder counter-clockwise (facing dash from underhood) to remove. 2.2L Turbo Diesel Models: Rotate master cylinder clockwise (facing dash from underhood) to remove. 
    CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.
    CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
    Fig 8: Clutch Master Cylinder Mounting - RHD
    GC0022839Courtesy of DAIMLERCHRYSLER CORP.
    1 - RESERVOIR
  14. Remove master cylinder assembly from mounting position and carefully work hydraulic pipe from out of engine compartment. See Fig 8.
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