Fluid Reservoir Removal; Installation; Brake Junction Block; Removal - Dodge dakota 2002 Service Manual

DR
FLUID RESERVOIR

REMOVAL

(1) Install the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the reservoir cap and siphon fluid into
a drain container (Fig. 34).
(3) Remove the electrical connector from the fluid
level switch in the reservoir (Fig. 34).
(4) Remove the reservoir mounting bolt (Fig. 34).
(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body (Fig.
34).
Fig. 34 FLUID RESERVOIR
1 - MASTER CYLINDER CAP
2 - FLUID RESERVOIR
3 - FLUID LEVEL SWITCH

4 - MASTER CYLINDER

5 - MOUNTING BOLT
6 - GROMMETS

INSTALLATION

CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate the new grommets with clean brake
fluid and Install new grommets in cylinder body. Use
finger pressure to install and seat grommets.
(2) Start the reservoir in grommets. Then rock the
reservoir back and forth while pressing downward to
seat it into the grommets.
(3) Install the mounting bolt for the reservoir to
the master cylinder.
(4) Reconnect the electrical connector to the fluid
reservoir level switch.
(5) Remove the prop rod from the vehicle.
(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).

BRAKE JUNCTION BLOCK

REMOVAL
(1) Remove the brake lines from the junction block
(Fig. 35).
(2) Remove the junction block mounting bolt and
remove the junction block from the bracket (Fig. 35).
Fig. 35 JUNCTION BLOCK
1 - BRAKE LINES
2 - JUNCTION BLOCK
INSTALLATION
(1) Position the junction block on the bracket and
install the mounting bolt. Tighten the mounting bolt
to 23 N·m (210 in. lbs.) (Fig. 35).
(2) Install the brake lines into the junction block
and tighten to 19-23 N·m (170-200 in. lbs.) (Fig. 35).
(3) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL
DARD PROCEDURE).
MASTER CYLINDER

DESCRIPTION

A two-piece master cylinder is used on all models.
The cylinder body containing the primary and sec-
ondary pistons is made of aluminum. The removable
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the
hydraulic brake circuits and has a switch for indicat-
ing low fluid levels. The reservoir is the only service-
able component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
BRAKES - BASE 5 - 19
- STAN-