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Home >> Chrysler >> 2009 >> PT Cruiser Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 8 (Mechanical Brake System - Base (Service Information)) >> Hydraulic/Mechanical >> MASTER CYLINDER, Brake >> Removal >> With Abs

With Abs

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Before proceeding. See Brakes - Warning  and Brakes - Caution .
CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
  1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
  2. Disconnect the negative (ground) cable from the battery and isolate the cable.
    Fig 1: BRAKE FLUID LEVEL SWITCH CONNECTOR
    GC0083908Courtesy of CHRYSLER LLC
  3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir.
    Fig 2: PRIMARY AND SECONDARY BRAKE TUBES TO ICU
    GC0083930Courtesy of CHRYSLER LLC
  4. Disconnect the primary (1) and secondary (2) brake tubes at the master cylinder outlet ports. Install plugs at all of the open brake tube outlets on the master cylinder.
    Fig 3: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER
    GC0083932Courtesy of CHRYSLER LLC
  5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1).
    Fig 4: MASTER CYLINDER MOUNTING NUTS
    GC0083933Courtesy of CHRYSLER LLC
  6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar® Brake Parts Cleaner or an equivalent.
  7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1).
  8. Slide the master cylinder straight out of the power brake booster.