1993 CHEVROLET DYNASTY brakes

MASTER CYLINDER INDEX
page page
Brake Fluid Level Sensor .................. 66
General Information ....................... 66 Master Cylinder Service Procedures
.......... 67
Testing the Master Cylinder ................. 66
GENERAL INFORMATION
The tandem master cylinder (Fig. 1) has a glass re-
inforced nylon reservoir and an anodized aluminum
body. Do not hone the bore of the cylinder, as this will
remove the anodized surface. The reservoir is indexed to prevent installation in
the wrong direction (Fig. 2). The cap diaphragms are
slit to allow atmospheric pressure to equalize on both
sides of the diaphragm. The primary and secondary outlet tubes from the
master cylinder are connected to the valve mounted
under the master cylinder. The front part of this
block connects to the secondary outlet tube and sup-
plies the right rear and left front brakes. The rear
portion of the block connects to the primary outlet
tube and supplies the right front and left rear
brakes.
BRAKE FLUID LEVEL SENSOR
The Brake Fluid Level sensor is found only in the
AJ body vehicles with the visual electronic message
center. The purpose of the sensor is to provide the
driver with an early warning message that brake
fluid in master cylinder reservoir has dropped to a
below normal. As the fluid drops below the design level the sensor
closes the warning message circuit. Approximately
15 seconds later the message BRAKE FLUID LOW
appears on the instrument panel. At this time the master cylinder reservoir should be checked and filled
to the bottom of the rings with DOT 3 brake fluid. To check the operation of the Brake Fluid Level
sensor, with ignition on and wiring still attache-
d,remove sensor from master cylinder and hold in
upright position. Within 30 seconds the instrument
panel message BRAKE FLUID LOW should appear.
Next invert the sensor. The instrument panel message
should turn off immediately. If the above sequence
occurs the sensor is operating properly. If the message
does not appear remove the wiring from the sensor and
using a jumper wire connect both sides of the plug. The
instrumental panel message BRAKE FLUID LOW
should appear within 30 seconds. If the message does
not appear a problem exists in the wiring or instru-
mentation. If the message does appear the sensor is
faulty and must be replaced. The Brake Fluid Level
sensor is not a repairable item (Fig. 2).
TESTING THE MASTER CYLINDER
Be sure master cylinder vents at both ports.
Apply pedal lightly with engine running and look for
fluid squirting or swirling into reservoirs. In this master cylinder, a special baffle reduces the
amount of fluid entering the secondary reservoir only a
small disturbance may be seen.
Fig. 1 Aluminum Master Cylinder (Cutaway View)
Fig. 2 Brake Fluid Level Sensor
5 - 66 BRAKES Ä

MASTER CYLINDER SERVICE PROCEDURES
MASTER CYLINDER REMOVAL
Disconnect primary and secondary brake tubes from
master cylinder housing. Install plugs at brake tube
outlets. Remove 2 nuts (Fig. 3) attaching master cylinder
housing to power brake booster unit.
Slide master cylinder straight out, and away from
power brake booster unit.
BRAKE FLUID RESERVOIR REPLACEMENT
Clean master cylinder housing and brake fluid res-
ervoir. Remove the brake fluid reservoir caps. Using a
syringe or equivalent empty brake fluid from reservoir. Position master cylinder in vise.
Rock reservoir from side to side and remove from
master cylinder housing (Fig. 4). Do not pry off with tool, damage to reservoir
may result. Remove housing-to-reservoir grommets (Fig. 5).
Install new housing-to-reservoir grommets in master
cylinder housing. Lubricate reservoir mounting area with clean brake
fluid. Place reservoir in position over grommets. Seat
reservoir with a rocking motion onto master cylinder
housing. Be sure reservoir is positioned properly. All lettering
should be properly read from the left side of the master
cylinder (Fig. 4). Make sure bottom of reservoir touches top of grom-
met.
BLEEDING MASTER CYLINDER
Clamp the master cylinder in a vise. Attach Bleeding
Tubes, Special Tool C-4546 to the master cylinder.
Position tubes so the outlet of the Bleeding Tubes will
be below the surface of the brake fluid when the
reservoir is filled to the proper level. Fill both reservoirs with brake fluid conforming to
DOT 3 specifications such as Mopar or Equivalent. Using a wooden dowel per (Fig. 6). Depress push rod
slowly, and then allow pistons to return to released
position. Repeat several times until all air bubbles are
expelled (Fig. 6). Remove bleeding tubes from cylinder, plug outlets
and install caps. Remove master cylinder from vise and install on
power brake vacuum booster. It is not necessary to bleed the entire hydraulic
system after replacing the master cylinder. But
the master cylinder must have been bled and
filled upon installation.
Fig. 4 Removing Reservoir
Fig. 5 Removing Grommets
Fig. 3 Master Cylinder Mounting
Ä BRAKES 5 - 67

INSTALLING MASTER CYLINDER
Position master cylinder over studs of power brake
unit, align push rod with master cylinder piston. Install the master cylinder to power brake unit
mounting nuts (Fig. 4) and tighten to 28 N Im (250 in.
lbs.) torque. Connect brake tubes to master cylinder primary and
secondary ports. Tighten fittings to 17 N Im (145 in-
.lbs.) torque.
POWER BRAKES
GENERAL INFORMATION
All vehicles, except non turbo charged AP bodies,
equipped with manual transmissions use a 205 mm
tandem booster. The non turbo charged manual trans-
mission equipped AP body application use a 230 mm
non-tandem booster. The purpose of the vacuum operated power brake
booster. Is to reduce the amount of force applied to the
brake pedal by the drivers foot. To obtain the required
hydraulic pressure in the brake system to stop the
vehicle. The power brake booster can be identified if required,
by the tag attached to the body of the booster assembly
(Fig. 1). This tag contains the following information.
The production part number of the power booster
assembly, the date it was built and who manufactured
it. The power brake booster assembly is not a
repairable part and must be replaced as a com-
plete unit if it is found to be faulty in any way.
The power booster vacuum check valve is not
repairable but can be replaceable as an assembly. The power brake booster is vacuum operated. The
vacuum is supplied from the intake manifold on the
engine through the power brake booster check valve
(Fig. 2). As the brake pedal is depressed, the power boosters
input rod moves forward. This opens and closes valves
in the power booster, creating a vacuum on one side of
a diaphragm and allowing atmospheric pressure to enter on the other. This difference in
pressure forces the output rod of the power booster
out against the primary piston of the master cylin-
der. As the pistons in the master cylinder move for-
ward this creates the hydraulic pressure in the brake
system. Different systems and engine combinations require
different vacuum hose routings.
Fig. 6 Bleeding Master Cylinder
Fig. 1 Power Brake Booster Identification
5 - 68 BRAKES Ä

The power brake booster assembly mounts on the
engine side of the dash panel. It is externally con-
nected to the brake system by an input push rod to
the brake pedal. A vacuum line connects the power
booster to the intake manifold. The master cylinder
is bolted to the front of the power brake booster as-
sembly (Fig. 3).
SERVICE PROCEDURES
POWER BRAKE BOOSTER ASSEMBLY
REMOVE
(1) Remove the 2 nuts (Fig. 4) attaching master
cylinder assembly to power brake unit.
(2) Carefully slide master cylinder off mounting
studs with brake lines attached, and allow the assem-
bly to rest against fender shield. (3) Disconnect vacuum hose from power brake
booster check valve (Fig. 1). DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER. (4) From under instrument panel, position a small
screwdriver between the center tang on the power
brake booster input rod to brake pedal pin retaining
clip. (5) Rotate screwdriver enough to allow retainer clip
center tang to pass over end of brake pedal pin and pull
retainer clip off pin. Discard retainer clip it is not
to be reused, replace only with a new retainer
clip. (6) Remove the four nuts that attach the power
brake booster to the vehicle dash panel. Nuts are
accessible from under the dash panel in the area of the
steering column and pedal bracket (Fig. 5).
Fig. 2 Power Brake Booster Assembly
Fig. 3 Power Brake Mounting
Fig. 4 Master Cylinder Mounting
Ä BRAKES 5 - 69

(7) Unfasten brackets on steel heater water line at
dash panel and left frame rail. On Manual Transmis-
sion vehicles, unfasten clutch cable bracket at shock
tower and move aside. (8) Slide the power brake unit up and to the left
(mounting holes are slotted) on the dash panel, then
tilt inboard and up to remove.
CAUTION: Do not attempt to disassemble power
brake unit as this booster is serviced ONLY as a
complete assembly.
INSTALL (1) Position power brake booster onto dash panel.
(2) Install and tighten the 4 power brake booster to
dash panel mounting nuts (Fig. 5) to 29 N Im (250 in.
lbs.) torque. (3) Install steel heater water line and clutch cable
bracket, if so equipped. (4) Carefully position master cylinder on power
brake unit. (5) Install and tighten the 2 master cylinder to
power booster mounting nuts (Fig. 4) to 29 N Im (250
in. lbs.) torque. (6) Connect vacuum hose onto the check valve, lo-
cated on the power brake unit. (7) Using lubriplate, or equivalent, coat the bearing
surface of pedal pin (Fig. 5). (8) Connect power brake booster input rod to brake
pedal pin and install a NEW retainer clip. Use only a
new retainer clip DO NOT USE the old clip. (9) Check stop light operation.
WHEEL BEARINGS
FRONT WHEEL BEARINGS
Front wheel drive vehicles are equipped with per-
manently sealed front wheel bearings. There is no
periodic lubrication or maintenance recommended for
these units. However if during servicing of the brake
system, service to the front wheel bearing is required
refer to Group 2, Suspension in this service manual.
REAR WHEEL BEARINGS
NORMAL SERVICE
The lubricant in the rear wheel bearings should be
inspected whenever the hubs are removed to inspect
or service the brake system. Or at least every 30,000
miles (48,000 km). The bearings should be cleaned
and repacked with a High Temperature Multipurpose
E.P. Grease whenever the disc brake rotors are re-
surfaced.
INSPECTION
Check lubricant to see that it is adequate in quan-
tity and quality. If the grease is low in quantity, con-
tains dirt, appears dry or has been contaminated
with water, it will appear milky. The bearings then must be cleaned and repacked.
Do not add grease to
a wheel bearing that already has grease packed
in it. Relubricate completely. Mixing of different
types of greases in wheel bearings should be
avoided since it may result in excessive thinning
and leakage of the grease.
REMOVAL AND INSTALLATION
For the servicing, removal and installation of the
rear wheel bearings follow the procedure listed below. (1) Remove the rear tire and wheel assembly.
(2) On rear disc brake equipped vehicles remove the
caliper and rotor. Support the caliper out of the way.
Do not allow the caliper to hang by the hydraulic
hose. See disc brake section in this group for caliper
removal procedure. (3) Remove grease cap, cotter pin, nut lock, nut,
thrust washer and outer wheel bearing. (4) Carefully slide hub or drum from spindle. Do not
drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.) Using
an appropriate tool remove the grease seal and inner
bearing from the drum or hub. Discard grease
Fig. 5 Power Brake Booster Mounting
5 - 70 BRAKES Ä

seal, a new seal should be used when reinstalling the
inner bearing. (See Fig. 1) (5) Thoroughly clean all old grease from the outer
and inner bearings, bearing cups and hub cavity (See
Fig. 1). To clean bearings, soak them in an ap-
propriate cleaning solvent. Strike the flat sur-
face of the bearing inner race against a
hardwood block several times. Immerse the
bearings in solvent between the blows to jar
grease loose and wash old particles of hardened
grease from bearings. Repeat this operation un-
til bearings are clean. Bearings can be dried
using compressed air but do not spin the bear-
ings. After cleaning, oil the bearings with engine
oil. Insert the bearing into its appropriate cup,
apply pressure to the bearing while rotating it to
test them for pitting and roughness. Replace all
worn or defective bearings. If bearing shows signs of pitting or roughness they should be
replaced. Bearings must be replaced as a set,
both the cup and the bearing need to be replaced
at the same time. If bearings are suitable for
further use, remove engine oil from bearings
using appropriate solvent and dry bearings. Re-
pack the bearings using a Multi-Purpose NLGI.
Grade 2 EP Grease such as Mopar or equivalent,
and place them in a clean covered container
until ready for installation. If a bearing packer is
not available, hand pack grease into all cavities
between bearing cage and rollers. (6) If bearings and cups are to be replaced, remove
cups from the drum or hub using a brass drift or
suitable remover. (7) Replace bearing cups with appropriate installing
tool. (8) Install inner bearing in grease coated hub and
bearing cup, and install new grease seals using the
appropriate seal installer. (9) Coat hub cavity and cup with grease.
(10) Before installing hub or drum assembly, inspect
stub axle and seal surface for burrs or roughness, and
smooth out all rough surfaces. (11) Coat the stub axle with Multi-Purpose NLGI,
Grade 2 EP grease such as Mopar or equivalent. (12) Carefully slide the hub of drum assembly onto
the stub axle. Do not drag seal or inner bearing
over the threaded area of the stub axle. (13) Install outer bearing, thrust washer and nut.
(14) Tighten the wheel bearing adjusting nut to 27 to
34 N Im (240 to 300 in. lbs.) while rotating hub or drum
assembly. This seats the bearings. (15) Back off adjusting nut 1/4 turn (90É) then
tighten adjusting nut only finger tight. (16) Position the nut lock over the bearing adjusting
nut with one pair of slots in line with the cotter pin hole
in the stub axle, and install cotter pin. (17) Install the grease caps and the wheel and tire
assemblies. Tighten wheel stud nuts to 115 N Im (85 ft.
lbs.) on all models. reinstall wheel covers if so
equipped.
Fig. 1 Rear Wheel Bearings
Ä BRAKES 5 - 71

ABS EQUIPPED VEHICLE PERFORMANCE
Anti-Lock Brakes provide the driver with some
steering control during hard braking. However there
are conditions where the system does not provide any
benefit. In particular, hydroplaning is still possible
when the tires ride on a film of water. Hydroplaning
results in the vehicle tires leaving the road surface
rendering the vehicle almost uncontrollable. In addi-
tion, extreme steering maneuvers at high speed or
high speed cornering beyond limits of tire adhesion
to the road surface may cause vehicle skidding. So,
the ABS system is termed Anti-Lock instead of Anti-
Skid. One of the significant benefits of the ABS system is
that of maintaining steering control during hard
braking or during braking on slippery surfaces. It is
therefore possible to steer the vehicle while braking
on almost any road surface.
ABS SYSTEM SELF-DIAGNOSTICS
The ABS system has been designed with Self Diag-
nostic Capability. There are two self checks the sys-
tems performs every time the vehicle is started.
First, when the key is turned on the system performs
an electrical check called Start-Up Cycle. During this
check, the Red Brake Warning Lamp and the Amber
Anti-Lock Warning Lamp are illuminated. Then
turned off at the end of the test, after about 1 to 2
seconds. When the vehicle reaches a speed of about 3
to 4 miles per hour. The system performs a func-
tional check called Drive-Off. During Drive-Off. hy-
draulic valves are activated briefly to test their
function. Drive-Off can be detected as a series of
rapid clicks upon driving off the first time the car is
started. If the brake pedal is applied during Drive-
Off, the test is by-passed. Both of these conditions
are a normal part of the system self test. Most fault
conditions will set a ABS Fault Code in the (CAB),
which can be retrieved to aid in fault diagnosis. De-
tails can be found in Diagnosis Section.
ABS WARNING SYSTEMS OPERATION
The ABS system uses two methods for notifying
the driver of a system malfunction. These include the
standard Red Brake Warning Lamp and an Amber
Anti-Lock Warning Lamp, both located in the instru-
ment cluster. The purpose of these two lamps are dis-
cussed in detail below.
RED BRAKE WARNING LAMP
The Red Brake Warning Lamp, located in the in-
strument cluster, will Turn On to warn the driver of
brake system conditions that may result in reduced
braking ability. The lamp is also turned on when the
parking brake is not fully released. Conditions which
may cause the Red Brake Warning Lamp to Turn On
include: ²
Parking brake not fully released. If the parking
brake is applied or not fully released. The switch on the
parking brake pedal assembly will ground the Red
Brake Warning Lamp circuit and cause the lamp to
turn on. On vehicles equipped with mechanical instru-
ment clusters, the Amber Anti-Lock Lamp will turn on
if the vehicle is driven above 3 miles per hour with the
Parking Brake applied.
² Low brake fluid. The fluid level sensor in the hy-
draulic assembly reservoir will ground the Red Brake
Warning Lamp circuit if low brake fluid level is de-
tected. In addition, ABS will be deactivated above 3
miles per hour and the Amber Anti-Lock Warning
Lamp will be illuminated. If the vehicle is equipped
with EVIC, a low fluid condition will also cause the
Low Brake Fluid message to appear.
² Low Accumulator Pressure. In the event of low
accumulator pressure, the dual function pressure
switch in the hydraulic assembly will signal the (CAB)
to ground the Red Brake Warning Lamp circuit. This
will cause the Red Brake Warning Lamp to turn on.
Low accumulator pressure also results in the activa-
tion of the Yellow Anti-Lock Warning Lamp. Low accu-
mulator pressure may result in loss of power assist.
² Modulator Or (CAB) Faults. The modulator assem-
bly or (CAB) may turn on the Yellow Anti-Lock Warn-
ing Lamp, if certain faults are detected in either the
modulator assembly or the (CAB).
² Bulb check. As a bulb check, the Red Brake Warning
Lamp will illuminate whenever the ignition switch is
placed in the crank position. Illumination of the red Brake Warning Lamp
may indicate reduced braking ability. A vehicle
that has the Red Brake Warning Lamp ON should
not be driven except to do diagnostic procedures
described in Section 2 of this manual. Most con-
ditions that turn on the Red Brake Warning
Lamp will also turn on the Amber Anti-Lock
Warning Lamp, consequently disabling the Anti-
Lock function.
ANTI-LOCK WARNING LAMP
The Anti-Lock Warning Lamp is located in the in-
strument cluster and is Amber in color. The Amber
Anti-Lock Warning Lamp is illuminated when the
(CAB) detects a condition that results in a shutdown of
Anti-Lock function. The Amber Anti-Lock Warning
Lamp is normally on until the (CAB) completes its self
tests and turns the lamp off. For example, if the (CAB)
is disconnected, the lamp is on. Display of the Amber Anti-Lock Warning Lamp
without the Red Brake Warning Lamp indicates
only that Anti-Lock function has been disabled.
Power assisted normal braking is unaffected.
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 75

NORMAL OPERATION OF WARNING LAMPS
With the ignition in the Crank position, the Red
Brake Warning Lamp will turn on as a bulb check.
The Amber Anti-Lock Warning Lamp will turn on
for as little as 1 second to as long as 30 seconds. If the car has not been started for several hours,
for example after sitting overnight. The Red Brake
Warning Lamp and the Amber Anti-Lock Warning
Lamp may both be turned on for as long as 60 sec-
onds after turning the ignition on. This condition is
caused by the loss of accumulator charge when the
vehicle is parked for extended periods, particularly in
cold weather. When the key is then turned on. The
Pump/Motor assembly must recharge the hydraulic
accumulator to its normal operating pressure. As re-
charging is completed, both warning lamps will turn
off when accumulator pressure reaches about (1,000
psi). Both lamps should remain off at all other times,
indicating normal operation.
ANTI-LOCK BRAKE SYSTEM COMPONENTS
The following is a detailed description of the Anti-
Lock Brake System components. For information on
servicing the other Non-ABS related components
that may be referred to in this section. See the Stan-
dard Brakes Section that refers to the specific com-
ponent.
HYDRAULIC ASSEMBLY
The ABS system uses an integral Hydraulic Assem-
bly (Fig. 1). The hydraulic assembly includes a
Booster/Master Cylinder, Modulator, Hydraulic Blad-
der Accumulator and Fluid Reservoir. The Hydraulic
Assembly is located on the dash panel cowl on the
drivers side of the vehicle. The following is a descrip-
tion of the components that make up the Hydraulic
Assembly.
HYDRAULIC ASSEMBLY BRAKE FLUID RES- ERVOIR
A one piece Fluid Reservoir is attached to the hy-
draulic assembly with rubber seals. The Fluid Reser-
voir (Fig. 1) is internally separated into three fluid
sections. Most of the brake fluid is contained in the
Fluid Reservoir and hydraulic bladder accumulator
(Fig. 1). Additional fluid is contained in the
pump/motor assembly accumulator.
BOOSTER/MASTER CYLINDER
The Booster/Master Cylinder portion of the
hydraulic assembly is an integral component and
should never be disassembled. The Booster/Master Cylinder uses a diagonally split
configuration during normal braking. The two
Fig. 1 Hydraulic Assembly
5 - 76 ANTI-LOCK 10 BRAKE SYSTEM Ä