Chrysler 68048548AA Brake Master Cylinder

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To remove the master cylinder, disconnect the cable(s) from the negative battery terminal(s), depress the brake pedal several times to remove all vacuum from the power brake booster, remove the master cylinder access cover in the cowl, clean the master cylinder and reservoir thoroughly with brake cleaner, remove as much fluid as possible from the reservoir with a syringe, unplug the electrical connector for the brake fluid level warning switch, place rags under the fittings, loosen the fittings at the ends of the brake lines where they enter the master cylinder using a flare-nut wrench, carefully move the brake lines away from the master cylinder, plugging the ends to prevent contamination, remove the master cylinder mounting nuts, and pull the master cylinder off the studs.

Fill the reservoir with the correct fluid and bleed the brake system by having an assistant pump the brake pedal and loosening the line fittings to allow air and fluid to escape until clear. Finally, complete the installation in reverse order and test the brake system operation before normal use.

To install the new master cylinder, bench bleed it before installing by mounting it in a vise and attaching a pair of master cylinder bleeder tubes to the outlet ports, fill the reservoir with brake fluid and slowly push the pistons into the master cylinder using a large Phillips screwdriver to expel air from the pressure chambers, repeat this procedure until no more air bubbles are present and remove the bleed tubes, installing plugs in the open ports to prevent fluid leakage and air from entering, install a new vacuum seal on the master cylinder and then install the reservoir cover, install the master cylinder over the studs on the power brake booster and tighten the attaching nuts finger tight, thread the brake line fittings into the master cylinder, being careful not to strip the threads, and tighten the mounting nuts and brake line fittings securely, fill the master cylinder reservoir with the correct fluid and bleed the brake system as described, and finally, test the operation of the brake system carefully before placing the vehicle into normal service.