(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
mounting nuts.
(b) Connect the wiring harness to the speed con-
trol servo.
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(d) Install the screw securing the coolant filler
neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 54). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
For information on master cylinder application,
bore and type, view the following table:
BRAKE SYSTEMMASTER CYLINDER
BORE/TYPE
Disc/Drum - ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Drum - Non-ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Disc - ABS27.0 mm (1-1/16 in.)
Conventional
Compensating Port
Disc/Disc ABS With
Traction Control27.0 mm (1-1/16 in.) Dual
Center Port
CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections.
The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir.
The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
Fig. 54 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RSBRAKES - BASE5-37
JUNCTION BLOCK (Continued)
ProCarManuals.com
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 55). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly.
The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358.
(2) Attach special tools for bleeding master cylin-
der in the following fashion:
(a)For non-traction control equipped mas-
ter cylinders, thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 56).
(b)For traction control equipped master
cylinders, thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 56).
Fig. 55 RHD MASTER CYLINDER AND POWER
BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
Fig. 56 Master Cylinder Set Up For Bleeding
1 - BLEEDER TUBES 8358
2 - WOODEN DOWEL
3 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL
EQUIPPED MASTER CYLINDERS)
4 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL
EQUIPPED MASTER CYLINDERS)
5 - 38 BRAKES - BASERS
MASTER CYLINDER (Continued)
ProCarManuals.com
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level.
(3) Fill brake fluid reservoir with Mopartbrake
fluid or equivalent conforming to DOT 3 (DOT 4 and
DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
(4) Using a wooden dowel as a pushrod (Fig. 56),
slowly depress master cylinder pistons, then release
pressure, allowing pistons to return to released posi-
tion. Repeat several times until all air bubbles are
expelled. Make sure fluid level stays above tips of
bleeder tubes in reservoir while bleeding.
(5) Remove bleeder tubes from master cylinder
outlet ports, then plug outlet ports and install fill cap
on reservoir.
(6) Remove master cylinder from vise.
(7) Install master cylinder on vehicle. (Refer to 5 -
BRAKES - BASE/HYDRAULIC/MECHANICAL/MAS-
TER CYLINDER - INSTALLATION)
REMOVAL
REMOVAL - LHD
CAUTION: Vacuum in the power brake booster must
be pumped down (removed) before removing mas-
ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle's engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4-5 strokes).
(2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
(5) Remove nut and clamp securing battery to tray,
remove battery.
(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as MopartBrake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 57).
(8) Disconnect primary and secondary brake tubes
from master cylinder housing (Fig. 57). Install seal-
ing plugs in the now open brake tube outlet ports.
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughlycleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(9) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(10) Remove two nuts attaching master cylinder to
power brake booster (Fig. 58).
(11) Slide master cylinder straight out of power
brake booster.
Fig. 57 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 58 MASTER CYLINDER MOUNTING
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
RSBRAKES - BASE5-39
MASTER CYLINDER (Continued)
ProCarManuals.com
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is
removed from master cylinder bycarefullypulling it
off the rear of master cylinder.Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
REMOVAL - RHD
CAUTION: Vacuum in the power brake booster must
be pumped down (removed) before removing mas-
ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle's engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4 or 5 strokes).
(2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
(5) Remove nut and clamp securing battery to tray,
remove battery.
(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as MopartBrake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 55).
(8) Disconnect primary and secondary brake tubes
from master cylinder housing (Fig. 59). Install seal-
ing plugs in the now open brake tube outlet ports.
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(9) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(10) Remove two nuts attaching master cylinder to
power brake booster (Fig. 59).
(11) Slide master cylinder straight out of power
brake booster.CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is
removed from master cylinder bycarefullypulling it
off the rear of master cylinder.Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Clean master cylinder housing and brake fluid
reservoir. Use only a solvent such as Mopar Brake
Parts Cleaner or an equivalent.
(2) Remove brake fluid reservoir cap. Using a
syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cylinder assembly from the
power brake vacuum booster. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER CYL-
INDER - REMOVAL).
(4) Mount the master cylinder in a vise using the
master cylinder mounting flange.
Fig. 59 RHD MASTER CYLINDER MOUNTING
1 - PRIMARY BRAKE TUBE NUT
2 - SECONDARY BRAKE TUBE NUT
3 - MASTER CYLINDER MOUNTING NUTS
5 - 40 BRAKES - BASERS
MASTER CYLINDER (Continued)
ProCarManuals.com
(5) Using correct size pin punch, remove the two
retaining pins between the fluid reservoir and master
cylinder housing (Fig. 60).
(6) Rock the brake fluid reservoir from side to side
while pulling up to remove it from the seal grommets
in master cylinder housing.
(7) Remove the two master cylinder housing to
brake fluid reservoir seal grommets (Fig. 61).
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Install new master cylinder housing to brake
fluid reservoir sealing grommets in master cylinder
housing (Fig. 61).(2) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir.
(3) Be sure fluid reservoir is positioned properly on
master cylinder.Bottom of fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.
(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 60).
(5) Install the master cylinder assembly on the
power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER CYLINDER -
INSTALLATION)
(6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION
INSTALLATION - LHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 58). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
57). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
Fig. 60 Fluid Reservoir Retaining Pins (Typical)
1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER
Fig. 61 Master Cylinder To Fluid Reservoir Seal
Grommets
1 - SEAL GROMMETS
2 - MASTER CYLINDER
RSBRAKES - BASE5-41
MASTER CYLINDER (Continued)
ProCarManuals.com
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
57).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
INSTALLATION - RHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 59). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
59). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
55).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.(11) Road test vehicle to ensure proper operation of
brakes.
PEDAL - ADJUSTABLE
DESCRIPTION
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
tions also allows the driver to set steering wheel tilt
and seat position to the most comfortable position.
The effort required for pedal application will not
change regardless of pedal position.
The adjustable pedal system allows the pedals to
adjust up to 3 inches (75 mm) at a rate of approxi-
mately 0.4 in./sec. (9 mm/sec.). An adjustment switch
is located on the left side of the steering column
lower shroud.
If the vehicle is equipped with Remote Keyless
Entry (RKE), an optional memory feature is avail-
able.
The serviceable components of the APS are:
²Adjustable pedal assembly (includes motor,
cables, pedals, gear box, sensor and module)
²Adjustable pedal module (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
ADJUSTABLE PEDAL MODULE)
²Adjustable pedal switch
²Pedal position sensor
OPERATION
Change of pedal position is accomplished by means
of a motor driven screw. Operating the adjustable
pedal switch activates the pedal drive motor. The
pedal drive motor turns a screw that changes the
position of the accelerator pedal. The motor also
drives a cable connected to a gear box that changes
the brake pedal position the same distance as the
accelerator pedal. The pedals can be moved rearward
(closer to the driver) or forward (away from driver).
Each pedal is moved on its activating lever to a posi-
tion where the driver feels most comfortable. The
position and operation of the activating levers are not
changed.
Pedal adjustment is inhibited when the vehicle is
in reverse or when cruise control is engaged. The
Electronic Vehicle Information Center (EVIC) will
display a message when the Adjustable Pedal Module
(APM) is disabled. i.e.:9Adjustable Pedal Disabled -
Cruise Control Engaged9or9Adjustable Pedal Dis-
abled - Vehicle in Reverse9.
Foot pressure or debris can stall pedal adjustment.
In order to avoid damage to system components dur-
5 - 42 BRAKES - BASERS
MASTER CYLINDER (Continued)
ProCarManuals.com
ing pedal adjustment, the APM will monitor pedal
position sensor voltage. If the APM does not detect
expected voltage change within 3 seconds, it will cut
power to the adjustable pedal motor.
An optional memory feature is available. This
allows storing of one or two preferred pedal positions
in the APS. A preferred position can be stored and
recalled using the door-mounted switches. A stored
pedal position can be recalled (but not stored) using
the Remote Keyless Entry (RKE) if equipped with
the memory feature.
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL SYSTEM
Refer to Appropriate Diagnostic Information.
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 62).(4) Disconnect parking brake release link at
release handle.
(5) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.
(6) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 62).
(7) Remove screws securing instrument panel
lower left reinforcement in place, then remove rein-
forcement (Fig. 63).
(8) Remove brake lamp switch. Discard the origi-
nal switch; it must not be reused (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL)
(9) Remove screws fastening upper and lower
steering column shrouds to steering column (Fig. 64).
(10) Remove the lower shroud with adjustable
pedal switch; disconnect switch wiring connector
along left side of column as shroud is removed (Fig.
65).
(11) Disconnect traction control off switch wiring
connector; Remove upper shroud with traction con-
trol off switch.
(12) Disconnect wiring harness connectors (as
equipped) from clockspring, multi-function switch,
halo lamp, SKIM module, ignition switch and BTSI
solenoid (Fig. 65).
(13) Disconnect column wiring harness routing clip
from column.
Fig. 62 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 63 Instrument Panel Lower Left Reinforcement
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT
RSBRAKES - BASE5-43
PEDAL - ADJUSTABLE (Continued)
ProCarManuals.com
(14) Disconnect PRNDL cable from shift lever and
column bracket (Fig. 66).
(15) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 66).(16) Remove pinch side clip, then remove shift
cable from bracket on column.
(17) Turn the steering wheel from the STRAIGHT-
AHEAD position 180É to the right (upside-down posi-
tion), then remove the key and lock the column in
place.
(18) Remove the pinch bolt securing column cou-
pling to intermediate shaft (Fig. 67).
Fig. 64 Steering Column Shrouds
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 65 Pedal Switch Wiring Connector
1 - STEERING COLUMN FIXED SHROUD
2 - BRAKE TRANSMISSION SHIFT INTERLOCK
3 - B.T.S.I. WIRING CONNECTOR
4 - PEDAL SWITCH WIRING CONNECTOR
Fig. 66 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE
5 - STEERING COLUMN
Fig. 67 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
5 - 44 BRAKES - BASERS
PEDAL - ADJUSTABLE (Continued)
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