Chrysler Concorde 2004 Service Manual page 1506

5 - 40 BRAKES - BASE BRAKE SYSTEM
MASTER CYLINDER (Continued)
DISASSEMBLY
(1) Remove the master cylinder from the power
brake booster. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - REMOVAL)
(2) Using an appropriate cleaner such as Mopar
Brake Parts Cleaner, clean the master cylinder hous-
ing and brake fluid reservoir.
(3) Remove the filler cap and empty all brake fluid
from reservoir.
(4) Clamp the master cylinder in vise.
(5) Remove the 2 fluid reservoir to master cylinder
retaining pins (Fig. 67).
Fig. 67 Reservoir Retaining Pins
1 - BRAKE FLUID RESERVOIR
2 - DRIFT
3 - RETAINING PIN
4 - MASTER CYLINDER
NOTE: Do not pry off fluid reservoir using a tool,
damage to reservoir may result.
(6) Remove reservoir from master cylinder by pull-
ing upward on the reservoir while rock it from side-
to-side (Fig. 68).
(7) Remove the master cylinder housing-to-reser-
voir grommets (Fig. 69).
(8) For reassembly, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
ASSEMBLY).
ASSEMBLY
(1) Install new housing-to-reservoir grommets in
master cylinder housing (Fig. 69).
(2) Lubricate brake
mounting area with clean brake fluid. Place reservoir
in position over grommets. Seat reservoir into sealing
grommets using a rocking motion while pushing
down on reservoir.
(3) Make sure bottom of reservoir touches the top
of both sealing grommets.
CYLINDER
fluid reservoir-to-grommet
Fig. 68 Removing Reservoir
1 - FLUID RESERVOIR
2 - MASTER CYLINDER
3 - SEALING GROMMETS
Fig. 69 Reservoir Sealing Grommets
1 - RESERVOIR SEALING GROMMETS
2 - MASTER CYLINDER
(4) Install the 2 fluid reservoir to master cylinder
retaining pins (Fig. 67).
(5) Bleed and install master cylinder on vehicle.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
MASTER CYLINDER - STANDARD PROCEDURE)
INSTALLATION
-
CAUTION: If the master cylinder is being replaced
or has been repaired, the master cylinder must be
bled before installation. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
STANDARD PROCEDURE)
(1) Install master cylinder on studs of power brake
vacuum booster, aligning the booster push rod with
master cylinder piston.
(2) Install the master cylinder mounting nuts (Fig.
66). Tighten the nuts to a torque of 28 N·m (250 in. lbs.).
(3) Connect brake tubes to master cylinder pri-
mary and secondary ports. Tighten fittings to 17 N·m
(145 in. lbs.) torque.
LH
CYLINDER -