Removal and Installation
Proportioning Valve Removal
1991
06-06-7 Hydraulic Brake System 06-06-7
REMOVAL AND INSTALLATION (Continued)
1. Remove two bolts from fuel filter bracket. Position fuel filter out of the way.
2. If necessary, remove the master cylinder and hydraulic actuation assembly (on ABS equipped vehicles) to gain access to the proportioning valve.
3. Using a tubing wrench, loosen all of the brake lines connected to the proportioning valve.
4. Using a tubing wrench, loosen the brakes lines at the master cylinder.
5. Remove the brake lines between the proportioning valve and the master cylinder.
6. Disconnect all brake lines connected to the proportioning valve.
1991
06-06-8 Hydraulic Brake System 06-06-8
REMOVAL AND INSTALLATION (Continued)
7. Remove the proportioning valve.
Installation
1. Position the proportioning valve on the bulkhead and loosely install one of the attaching bolts.
2. Loosely install the brake lines between the master cylinder and the proportioning valve.
3. Loosely install the six brake lines into the proportioning valve.
4. Install the other attaching bolt in the proportioning valve and tighten both bolts to 19-23 N-m (14-17 lb.ft.).
5. Using a tubing wrench, tighten all brake lines to 13-22 N-m (10-16 lb.ft.).
6. If removed, install the hydraulic actuation assembly and the master cylinder.
7. Bleed the brakes. If necessary, refer to the Brake Bleeding procedure in this Section. If the system is being manually bled, bleed the lines at the proportioning valve first and then at the wheels.
Stoplamp Switch
If the stoplamp switch needs to be serviced, refer to the procedure in this Section.
Master Cylinder (Except ABS)
Removal
1. Disconnect the low fluid level sensor wiring.
2. Using a tubing wrench, loosen the brake lines at the master cylinder.
3. Disconnect the brake lines from the master cylinder.
4. Cap the lines and the master cylinder ports.
5. Remove the attaching nuts and the master cylinder.
Installation
1. Position the master cylinder and install the
attaching nuts. Tighten the nuts to 10-16 N-m (8-12 lb.ft.).
2. Connect short lengths of brake line to the master cylinder that point back into the reservoir.
3. Fill the reservoir with DOT-3 brake fluid and pump the brake pedal until clear fluid comes out of both temporary brake lines.
4. Place a shop towel over the top of the reservoir.
1991
06-06-9 Hydraulic Brake System 06-06-9
REMOVAL AND INSTALLATION (Continued)
5. Remove the temporary brake lines.
6. Connect the brake lines to the master cylinder and tighten the nuts to 13-22 N-m (10-16 lb.ft.).
7. Fill the reservoir up to the proper level with DOT-3 brake fluid and bleed the brakes. If necessary, refer to the Brake Bleeding procedure in this Section.
Master Cylinder (With ABS)
Removal
1. Disconnect the electrical connector leading to the fluid level sensor.
2. Remove the banjo bolts from the master cylinder.
1991
06-06-10 Hydraulic Brake System 06-06-10
REMOVAL AND INSTALLATION (Continued)
3. Cap the brake lines and the master cylinder ports.
4. Remove the mounting nuts and washers.
5. If equipped, remove the clutch pipe bracket.
6. Remove the master cylinder.
Installation
1. Check, and if necessary, adjust the push rod clearance. Refer to Section 06-07.
2. Position the master cylinder and clutch pipe bracket (if equipped), then install the mounting nuts and washers. Tighten the nuts to 10-16 N-m (8-12 lb.ft.).
3. Uncap the brake lines and the master cylinder ports.
4. Install the banjo bolts and tighten to 20-29 N-m (14-22 lb.ft.).
5. Connect the fluid level sensor electrical connector.
6. Fill the reservoir up to the proper level with the specified brake fluid. Bleed the brakes as explained in this Section.
Brake Pedal
Removal
1. Remove the spring clip and clevis pin from the brake pedal.
2. Remove the nut, lockwasher and washer from the pedal bolt.
3. Slide pedal bolt all the way to the left. Remove the spacer.
4. Tilt pedal to the left. Remove the pedal assembly.
5. Remove the pedal bolt from the pedal bracket.
6. Remove the return spring from the brake pedal.
7. Remove the pedal bushings from the pedal.
1991
06-06-11 Hydraulic Brake System 06-06-11
REMOVAL AND INSTALLATION (Continued)
Installation
1. Apply white lithium grease to the pedal bushings and clevis pin.
2. Install the pedal bushings in the pedal.
3. Position the return spring on the pedal. Use a piece of tape to hold the spring in position.
4. Install the pedal bolt in the pedal bracket, pedal and spacer.
5. Install the washer, lockwasher, and nut on the pedal bolt.
6. Position the clevis on the brake pedal.
7. Install the clevis pin in the clevis and brake pedal. Install the spring clip on the clevis pin.
Caliper Hose
Removal
1. Remove the retainer clip from the flex hose attaching it to the strut.
2. Using a tubing wrench, loosen and remove the brake line fitting where it attaches to the flex hose.
3. Remove the retainer clip from the end of the flex hose.
4. Remove the banjo bolt from the flex hose and separate it from the caliper.
5. Discard the two copper washers that seal the banjo fitting.
Installation
1. Install two new copper washers and the banjo bolt on the banjo fitting.
2. Position the flex line against the caliper and loosely install the banjo bolt.
3. Position the other end of the flex line in its bracket on the body and loosely install the brake line fitting.
4. Install the two retainer clips at the support brackets.
5. Tighten the banjo bolt at the caliper and the brake line fitting at the other end of the flex hose.