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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 >> Without Abs

Without 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. Remove 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 FRONT BRAKES
    GC0102543Courtesy of CHRYSLER LLC
  4. Disconnect the two front brake tubes (1, 2) from the master cylinder. Install plugs at the open brake tube outlets on the master cylinder.
    Fig 3: PRIMARY AND SECONDARY BRAKE TUBES TO REAR BRAKES
    GC0102541Courtesy of CHRYSLER LLC
  5. Disconnect the two rear brake tubes (1, 2) from the proportioning valves on the master cylinder (3). Install plugs at the open brake tube outlets on the proportioning valves.
    Fig 4: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER
    GC0083932Courtesy of CHRYSLER LLC
  6. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1).
    Fig 5: MASTER CYLINDER MOUNTING NUTS
    GC0083933Courtesy of CHRYSLER LLC
  7. 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.
  8. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1).
  9. Slide the master cylinder straight out of the power brake booster.
  10. To remove the proportioning valves, unthread each from the master cylinder.