The ABS brake master cylinder rear seal may allow air ingestion into the cylinder and cause spongy brake feel or partial brake system loss. To correct this condition, the build date code of the master cylinder must be inspected and all master cylinders having a date code of 3309 and earlier must be replaced.

IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.

Details of this service action are explained in the following sections.

Service Procedure Videotape

No videotape of the service procedure for this recall will be provided.

Dealer Notification & Vehicle List

Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the incomplete involved vehicles by Certified Mail.

Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information.

The Vehicle List is arranged in Vehicle Identification Number (YIN) sequence.

Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

All dealers: Each Dodge and Chrysler­Plymouth dealer will receive a copy of this dealer recall notification letter by first class mail.

DIAL System Function 70

All involved vehicles were entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.

Parts

Important: Our records indicate that most of the involved vehicles have been serviced as a result of the January 21, 1994 DMAIL Message. Therefore, no parts will be distributed initially to dealers. Dealers are requested to order ABS Brake Master Cylinder Packages, PN 4762628, only to support scheduled repairs.

Each parts package contains the following components:

Quantity Description

1 ABS Brake Master Cylinder

1 Seal, Power Brake Booster Vacuum

Owner Notification and Service Scheduling

All incomplete involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect the master cylinder date code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Service Procedure

A. Inspect Master Cylinder Date Code
1. The date code is the TOP code located on the front (forward) boss of the aluminum master cylinder, and consists of 4 numbers and a letter (the letter is not important for this service). The first number indicates the calendar year built and the next three numbers indicate the day of the year. Any master cylinders with a date code of 3309 or earlier must be replaced (Figure 1).

2. If the master cylinder date code is 3310 or later, no further action is required. If the date code is 3309 or earlier, replace the master cylinder as instructed in Section B.

B. Replace Master Cylinder
1. With the engine off, pump the brake pedal until a firm pedal is achieved (4­5 strokes).
CAUTION: Vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination.
2. Remove vehicle wiring harness connector from brake fluid level sensor (Figure 2)
3. Disconnect the primary and secondary brake tubes from master cylinder housing (Figure 3). Install plugs at both open brake tube outlets.
Note: Clean brake tube connections and master cylinder to booster area with a suitable brake cleaner before disconnecting tubes.
4. Remove the 2 nuts attaching the master cylinder to the power brake vacuum booster and slide the master cylinder straight out of the booster (Figure 4).
5. Remove the vacuum seal located in the front of the power brake vacuum booster by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal. Then pry seal out of the booster (Figure 5).
Caution: Do NOT attempt to pry seal out of power brake vacuum booster by inserting a tool between the seal and the brake booster.
6. Clamp the provided master cylinder in a vise and attach Bleeding Tubes, Special Tool 6802 to the master cylinder (Figure 6). Position tubes so outlets of Bleeding Tubes will be below surface of brake fluid when reservoir is filled to the proper level.
7. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent.
8. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled (Figure 6).
9. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. Remove master cylinder from vise.
Note: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled prior to installation.
10. Make sure brake booster vacuum seal on master cylinder push rod is positioned with notches on vacuum seal pointing toward master cylinder housing, and that seal is seated against master cylinder housing (Figure 7). Remove plastic protector from master cylinder push rod.
11. Align push rod on power brake vacuum booster with master cylinder push rod and install the master cylinder straight onto the power brake unit mounting studs (Figure 4).
12. Install master cylinder mounting nuts and torque to 250 in­lbs. (28 N · m).
13. Remove plugs and connect brake tubes to master cylinder primary and secondary ports (Figure 3). Then torque all tube nuts to 145 in­lbs. (17 N · m).
14. Connect brake fluid level sensor wiring connector (Figure 2).
15. Top off master cylinder reservoir as necessary. Start engine and pump brake pedal firmly several times to assure of proper pedal travel and feel. Then check the system for leaks.

Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Add the cost of the recall parts package plus applicable dealer allowance to your claim.
If you pick up and deliver a customer's vehicle, provide a loaner, etc. submit a separate claim and use labor operation number 95234150 for up to $50 in the special service section of the claim.

Parts Return
Initially, a small number of master cylinders are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded.

Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions.

Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre­addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation 429­10­04
P.O. Box 1919
Detroit, Michigan 48231­1 919

Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.