The brake master cylinder rear piston seal may leak and cause a partial brake system loss To correct this condition, the master cylinder primary piston assembly must be replaced

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70 or VIP.

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 involved vehicles by first class mail.

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 other dealers: Each Dodge and Chrysler­Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail

DIAL System Function 70 and VIP

All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed

Parts

Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.

Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Primary Piston Packages, Recall PN CBEA6871 for ABS equipped vehicles and CBGA6872 for NON­ABS equipped vehicles, to service about 25% of those vehicles.

Each parts package contains the following components:

Owner Notification and Service Scheduling

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. 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 Code:

1. Inspect the front surface of the master cylinder for one of the following bottom codes as shown in figure 1 (the letter code is not important for this service):

· ABS equipped JA vehicles (TWO master cylinder brake tubes) with a code of 3895;
· NON­ABS equipped JA vehicles (FOUR master cylinder brake tubes) with a code of 3893; or
· NON­ABS equipped PL vehicles (FOUR master cylinder brake tubes) with a code of 3815
If the master cylinder has one of the above four digit codes, replace the primary piston as instructed in Section B (verify that the vehicle has not already been repaired by using DIAL system function 70 or VIP). If the master cylinder has any other bottom code, no further action is required.

B. Replace Master Cylinder Primary Piston:

1. Clean master cylinder and attaching area of power brake booster with Mopar Glass Cleaner PN 4318014.
2. 2.4L engine equipped vehicles: Remove the air cleaner resonator/housing for greater access to master cylinder.
3. Speed control equipped vehicles: Remove mounting nuts and set speed control servo aside for greater access to master cylinder.
4. Disconnect wiring to master cylinder reservoir brake fluid level sensor.
5. Disconnect the primary and secondary brake tubes from master cylinder. Install provided plugs into master cylinder outlet ports and cap the brake tubes.
Note: DO NOT drip brake fluid on painted surfaces as this may damage paint.
6. Remove the two nuts attaching the master cylinder to the brake booster. Slide the brake tube mounting bracket from the inboard master cylinder mounting stud and slide master cylinder off the brake booster mounting studs.
7. Drain brake fluid from the master cylinder reservoir.
8. Clamp master cylinder in a vice at the mounting flange area. Thoroughly clean master cylinder and reservoir with Mopar Glass Cleaner PN 4318014 and wipe with a clean cloth.
Caution: DO NOT use this cleaner on any internal master cylinder components or on the master cylinder piston bore.
9. ABS equipped vehicles only: Using a screw driver, pry away from the fluid level sensor and remove reservoir from master cylinder as shown in figure 2. Be careful not to damage the fluid level switch and KEEP MASTER CYLINDER CLEAN AT ALL TIMES.

10. ABS equipped vehicles only:

a. Remove and discard only the rear reservoir grommet and note which hole the primary piston retaining pin is in (Figure 3).
b. Remove the master cylinder from the vice and turn the master cylinder upside down. Using the provided dowel rod, stroke the piston to allow the retaining pin to fall out, then remove the primary piston (Figure 4). Discard the old pin and piston.
Note: If necessary, use a magnet while stroking the piston to remove the pin. Piston removal may require air pressure. Apply compressed air (regulated to about 20 psi) to the primary outlet, while blocking the rear reservoir opening. Be sure to wear safety goggles.

11. NON­ABS equipped vehicles only:

Using the supplied dowel rod, stroke and hold the primary piston and remove the snap ring from the rear of the master cylinder, then remove the primary piston (Figure 5). Discard the old piston and snap ring.
Caution: Be careful not to damage cylinder bore when using snap ring pliers.
Note: Piston removal may require air pressure. Install the reservoir cap and apply compressed air (regulated to about 20 psi) to one primary outlet, while blocking the other primary outlet. Be sure to wear safety goggles.

12. With CLEAN HANDS, rinse the inside of the master cylinder and lubricate both of the seals on the new primary piston assembly with clean brake fluid conforming to DOT 3 specifications. Insert the new piston assembly spring end first.
Note: ABS pistons must be installed with the piston slot in a vertical position to allow for piston pin installation (Figure 4).

13. ABS equipped vehicles only:

a. Using supplied dowel rod, stroke and hold the primary piston approximately 3/4 inch. Insert new retaining pin into the same hole in master cylinder body that the original retaining pin was in (Figure 3). When inserted properly, the end of pin should be almost flush with master cylinder surface (Figure 6).
b. Remove front reservoir grommet from the master cylinder body and discard. Verify that both primary and secondary piston pins are seated (end of pins are almost flush with surface as shown in figure 6). Lubricate two provided reservoir grommets with clean brake fluid and install grommets into the master cylinder body.
c. Install reservoir onto master cylinder body using a rocking motion (fluid level sensor must be on outboard side when installed in vehicle). There must be no reservoir­to­grommet gaps, or grommet­to­master cylinder body gaps. If gaps exist, the piston pins may not be fully inserted (Figure 6).
Caution: Make sure piston pins are inserted properly and that the grommets do not contact the ends of either pin. Failure to insert pins will cause brake drag.

14. NON­ABS equipped vehicles only:

Using the supplied dowel rod, stroke and hold the primary piston assembly beyond the snap ring groove in the master cylinder body and install provided snap ring (Figure 5).
Caution: Make sure snap ring is fully seated in groove. Be careful not to damage cylinder bore when using snap ring pliers.

15. Attach Miller Special Tool #6802 bleed tubes to primary and secondary outlets and position tubes so the outlets will be submerged in brake fluid when reservoir is filled. Fill master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. Bench bleed master cylinder by using the provided dowel rod. Slowly depress pistons with dowel rod, then allow pistons to return to the fully released position. Repeat this step several times after no air bubbles are expelled from the bleed tubes. This will insure all air is bled from the master cylinder (Figure 7).

Note: DO NOT install the master cylinder without following the above bench bleeding procedure. When this procedure is followed, it is not necessary to bleed the entire vehicle brake system.

16. Remove the bleed tubes from the master cylinder outlet ports. Verify that brake fluid drips from both the primary and secondary outlet ports. Plug outlet ports with the supplied plugs, top off reservoir with brake fluid and install reservoir cap.

Note: If brake fluid does not drip from the primary and/or secondary outlet ports, the master cylinder must be disassembled and the appropriate compensation port cleaned. On ABS master cylinders, no fluid dripping from an outlet port may also be caused by a missing/damaged piston pin or damaged piston center valve.

17. Install master cylinder assembly onto power brake booster studs. Align brake booster push rod with hole in master cylinder primary piston, then seat master cylinder against booster. Slide brake tube support bracket onto inboard mounting stud. Torque two attaching nuts to 250 in­lbs (28 Nm).

18. Remove master cylinder and brake tube plugs and attach brake tubes to master cylinder. Torque tube nuts to 145 in­lbs. (17 Nm).

19. Attach wiring connector to reservoir brake fluid level sensor.
20. Verify proper brake warning lamp operation by removing the reservoir cap and using the provided dowel rod (make sure rod is clean) to push the float to the bottom of its travel (Figure 8). With the key in the ON position and the float at the bottom of its travel the warning light should be illuminated. Reinstall reservoir cap.
21. With engine off, pump brake pedal about 3­4 times until all vacuum in power brake booster is depleted. Apply light brake pedal pressure and hold for a minimum of 30 seconds. The brake pedal should remain firm. Apply heavy brake pedal pressure and hold for a minimum of 30 seconds. Again, the brake pedal should remain firm. If the brake pedal drops or is not firm during either of these tests, the master cylinder may either have a damaged piston assembly or it was not properly bled and must be repaired accordingly.
22. Speed control equipped vehicles: Install speed control servo and tighten nuts securely.
23. 2.4L engine equipped vehicles: Install air cleaner resonator/housing.
24. Verify that no brake fluid leaks exists and road test vehicle to assure proper brake operation.

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.
Note: See the Warranty Administration Manual, Recall Claim Processing section for complete recall claim processing instructions.

Parts Return
Not required.

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
CIMS 482­00­85
800 Chrysler Drive East
Auburn Hills, Michigan 48326­2757

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.