Dodge Journey: Disassembly, Assembly

DISASSEMBLY

NOTE: If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir.

1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar Brake Parts Cleaner or equivalent.

2. Remove the brake fluid reservoir cap. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir.

Brakes
Fig. 100: REMOVING RESERVOIR FROM MASTER CYLINDER PINS

3. Remove the four reservoir retaining tabs from the mounting posts on the master cylinder housing.

4. Pull the reservoir straight up and remove it from the grommet seals in master cylinder housing.

Brakes
Fig. 101: SEAL ON REAR OF MASTER CYLINDER

5. Remove the vacuum O-ring seal (2) from the master cylinder mounting flange (1).

ASSEMBLY

NOTE: If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir.

Brakes
Fig. 102: SEAL ON REAR OF MASTER CYLINDER

1. Install a NEW vacuum O-ring seal (2) on the master cylinder mounting flange (1) making sure the O-ring fits evenly against the mounting flange.

Brakes
Fig. 103: Grommet Seals

2. Lubricate the reservoir mounting area with fresh clean brake fluid. With the grommet seals (2) on the fluid reservoir spigots, place the reservoir in position over the master cylinder. Install the fluid reservoir by firmly pressing down on the fluid reservoir. Once installed, make sure the fluid reservoir is touching the top of both grommet seals.

3. Push the reservoir retaining tabs over the mounting posts on the master cylinder housing. Make sure the retaining tabs are securely engaged.

4. Fill and thoroughly bleed the master cylinder before installing it.

5. Install the master cylinder.

    Removal
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