Master Cylinder - RHD

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary 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.

With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes).

Fig 1: Disconnecting/Connecting Battery Cables
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect and isolate battery negative cable (2) from battery post.

Fig 2: COWL ACCESS PANEL - RHD
Courtesy of DAIMLERCHRYSLER CORP.
Remove access panel (1) in cowl area to expose master cylinder.
Thoroughly clean all surfaces of brake fluid reservoir and master cylinder. Use only Mopar® Brake Parts Cleaner or equivalent.

Fig 3: EVAP/PURGE SOLENOID
Courtesy of DAIMLERCHRYSLER CORP.
Remove purge solenoid (1) from mount (2) and move it to side leaving hoses and wiring connected.

Fig 4: Brake Master Cylinder And Fluid Level Sensor Connection
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect wiring harness connector (4) from brake fluid level sensor (2) in master cylinder brake fluid reservoir (1).

Fig 5: Brake Tubes At Master Cylinder
Courtesy of DAIMLERCHRYSLER CORP.
Remove primary (3) and secondary (2) brake tubes from master cylinder (4). Install sealing plugs in open brake tube outlet ports.

Fig 6: Master Cylinder Mounting Nuts
Courtesy of DAIMLERCHRYSLER CORP.

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. Use only Mopar® Brake Parts Cleaner or equivalent.
Remove two nuts (2) attaching master cylinder (3) to power brake booster (1).
Slide master cylinder (3) straight out of power brake booster (1).

Fig 7: VACUUM SEAL ON REAR OF MASTER CYLINDER
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Vacuum seal (1) on rear of master cylinder (2) is used to allow vacuum ability in power brake vacuum booster. Vacuum seal MUST be replaced whenever master cylinder is removed from power brake vacuum booster.
Remove vacuum seal (1) located on mounting flange of master cylinder (2). Vacuum seal is removed 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. Damage can occur.