Chrysler Concorde 2004 Service Manual page 1504

5 - 38 BRAKES - BASE BRAKE SYSTEM
BRAKE JUNCTION BLOCK (Continued)
(6) Tighten the remaining junction block bracket-
to-engine cradle crossmember mounting bolt to 26
N·m (230 in. lbs.) torque.
(7) Install the four chassis brake tubes (going to
each brake) to the junction block (Fig. 62). Tighten
the tube fittings to 17 N·m (145 in. lbs.) torque with
the aid of a crow foot wrench.
(8) Install the two brake tubes coming from the
primary and secondary master cylinder ports to the
top rear corners of the junction block (Fig. 62).
Tighten the tube fittings to 17 N·m (145 in. lbs.)
torque with the aid of a crow foot wrench.
(9) Install the transmission control module (with
speed control servo attached) in its normal position
(Fig. 61). Install the nut and screw securing it in
place
(10) Install the transmission
mounting nut and screw securing it in place. Tighten
the screw to 6 N·m (45 in. lbs.). Tighten the nut to 12
N·m (107 in. lbs.) torque.
(11) Install the screw attaching the washer filler
tube to the upper radiator closure panel (Fig. 60).
(12) Install the screw attaching the speed control
servo to the upper radiator closure panel (Fig. 60).
(13) Remove the brake pedal holding tool.
(14) Bleed the base brake system. (Refer to 5 -
BRAKES - BASE - STANDARD PROCEDURE)
MASTER CYLINDER
DESCRIPTION
There are two different master cylinders used on
this vehicle. A center-port master cylinder is used on
ABS and Traction Control vehicles. A conventional
vent-port master cylinder is used on vehicles without
ABS. Both master cylinders appear the same exter-
nally except for the size of their outlet ports. The
ABS master cylinder has outlet ports differing in
size; the primary port is machined to accept a 12 mm
tube nut, while the secondary port is machined for a
10 mm tube nut. Both the primary and secondary
ports on a non-ABS master cylinder are machined to
accept 12 mm tube nuts.
The master cylinder is mounted to the face of the
power brake booster on the left side of the dash (Fig.
64). It has the brake fluid reservoir mounted on top
and the brake fluid level switch is mounted in the
side of that reservoir.
OPERATION
When the brake pedal is pressed, the master cylin-
der primary and secondary pistons apply brake pres-
sure through the
proportioning valves to each brake assembly. The
control
chassis brake tubes
module
1 - BOOSTER
2 - MASTER CYLINDER
3 - MASTER CYLINDER FLUID RESERVOIR
4 - FLUID LEVEL FULL MARK
5 - FLUID LEVEL SWITCH
brake fluid reservoir supplies the brake hydraulic
system with the necessary fluid to operate properly.
The primary and secondary outlet tubes of the
master cylinder are connected to a junction block on
non-ABS equipped vehicles. The tube from the mas-
ter cylinder primary outlet port connects to the
inboard port of the junction block, and the tube from
the secondary outlet port connects to the outboard
port of the junction block. The inboard port of the
junction block supplies the right front and left rear
brakes. The outboard port of the junction block sup-
plies the left front and right rear brakes.
On vehicles equipped with Antilock Brakes (with or
without Traction Control), the master cylinder pri-
mary outlet port outlet tube connects to the inboard
port of the ICU, and the secondary outlet port outlet
tube connects to the outboard port of the ICU.
The master cylinder reservoir cap diaphragm is slit
to allow atmospheric pressure to equalize on both
sides of the diaphragm.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping the master cylinder in a
vise for bleeding, carefully tighten the vise just
enough to hold the master cylinder from moving.
Excessive pressure can damage the master cylin-
der.
(1) Clamp master cylinder in a vise.
and
Fig. 64 Master Cylinder
LH