Service Procedure
A. DS (Ram 1500 Truck) Brake Tube Replacement1. Open the hood and disconnect the negative battery cable.
2. Install a prop rod on the brake pedal to keep pressure on the brake system.
NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tubes are being replaced. This will facilitate bleeding only the tubes from the master cylinder to the Hydraulic Control Unit (HCU).
3. Disconnect the primary and secondary brake tubes at the master cylinder (Figure 1).
4. Disconnect the primary and secondary brake tubes at the HCU (Figure 1).
5. Remove the primary and secondary brake tubes as an assembly.
CAUTION:
Use extreme care not to allow brake fluid to spill while removing the brake tubes.
6. Place the secondary brake tube into position.
7. Connect the secondary brake tube to the HCU. Hand tighten the tube nut.
8. Connect the secondary brake tube to the master cylinder. Hand tighten the tube nut.
9. Tighten the secondary brake tube nut at the master cylinder to 170 in.lbs. (19 N.m).
10. Place the primary brake tube into position.
11. Connect the primary brake tube to the HCU. Hand tighten the tube nut.
12. Connect the primary brake tube to the master cylinder. Hand tighten the tube nut.
13. Tighten the primary brake tube nut at the master cylinder to 170 in. lbs. (19 N.m).
14. Transfer the two brake tube retainers from the original brake tubes to the replacement brake tubes.
15. Discard the two original brake tubes.
16. Tighten both the primary and secondary brake tube nuts at the HCU until snug.
17. Remove the brake pedal prop rod.
18. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 3 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the primary HCU brake tube nut 1/4 turn for two seconds and then retighten the tube nut.
d. Repeat Steps 18a through 18c until all air has been removed from the system.
e. Repeat Steps 18a through 18d for the secondary HCU brake tube nut.
19. After both circuits have been bled, tighten the HCU brake tube nuts to 170 in. lbs. (19 N.m).
20. Check brake fluid level and add DOT 3 brake fluid as required.
21. Verify that there are no brake fluid leaks and that the brakes operate properly.
22. Connect the negative battery cable.
B. JK (Jeep Wrangler LHD) Brake Tube Replacement
1. Open the hood and disconnect the negative battery cable.
2. Install a prop rod on the brake pedal to keep pressure on the brake system.
NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tube is being replaced. This will facilitate bleeding only the tubes from the master cylinder to the Hydraulic Control Unit (HCU).
3. Disconnect the primary brake tube at the master cylinder (Figure 2).
4. Disconnect the primary brake tube at the HCU (Figure 2).
5. Remove the primary brake tube from the vehicle.
CAUTION:
Use extreme care not to allow brake fluid to spill while removing the brake tube.
6. Discard the old brake tube.
7. Place the new primary brake tube into position.
8. Connect the primary brake tube nut to the HCU. Hand tighten the tube nut.
9. Connect the primary brake tube nut to the master cylinder. Hand tighten the tube nut.
10. Tighten the primary brake tube nut at the master cylinder to 170 in. lbs. (19 N.m).
11. Tighten the primary brake tube nut at the HCU until snug.
12. Remove the brake pedal prop rod.
13. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 3 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the primary HCU brake tube nut 1/4 turn for two seconds and then retighten the tube nut.
d. Repeat Steps 18a through 18c until all air has been removed from the system.
14. After the primary circuit has been bled, tighten the HCU brake tube nut to 170 in. lbs. (19 N.m).
15. Check brake fluid level and add DOT 3 brake fluid as required.
16. Verify that there are no brake fluid leaks and that the brakes operate properly.
17. Connect the negative battery cable.
C. JK (Jeep Wrangler RHD) Brake Tube Replacement
1. Open the hood and disconnect the negative battery cable.
2. Install a prop rod on the brake pedal to keep pressure on the brake system.
NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tube is being replaced. This will facilitate bleeding only the tubes from the master cylinder to the Hydraulic Control Unit (HCU).
3. Disconnect the brake fluid level switch at the brake fluid reservoir.
4. Disconnect the primary brake tube at the master cylinder (Figure 3).
5. Disconnect the primary brake tube at the HCU (Figure 3).
6. Remove the primary brake tube from the vehicle.
CAUTION:
Use extreme care not to allow brake fluid to spill while removing the brake tube.
7. Discard the old brake tube.
8. Place the new primary brake tube into position.
9. Connect the primary brake tube nut to the HCU. Hand tighten the tube nut.
10. Connect the primary brake tube nut to the master cylinder. Hand tighten the tube nut.
11. Tighten the primary brake tube nut at the master cylinder to 170 in. lbs. (19 N.m).
12. Connect the brake fluid level switch at the brake fluid reservoir.
13. Tighten the primary brake tube nut at the HCU until snug.
14. Remove the brake pedal prop rod.
15. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 3 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the primary HCU brake tube nut 1/4 turn for two seconds and then retighten the tube nut.
16. After the primary circuit has been bled, tighten the HCU brake tube nut to 170 in. lbs. (19 N.m).
17. Check brake fluid level and add DOT 3 brake fluid as required.
18. Verify that there are no brake fluid leaks and that the brakes operate properly.
19. Connect the negative battery cable.
D. KA (Dodge Nitro) Brake Tube Replacement
1. Open the hood and disconnect the negative battery cable.
2. Install a prop rod on the brake pedal to keep pressure on the brake system.
NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tube is being replaced. This will facilitate bleeding only the tubes from the master cylinder to the Hydraulic Control Unit (HCU).
3. Disconnect the brake fluid level switch at the brake fluid reservoir.
4. Disconnect the primary brake tube at the master cylinder (Figure 4).
5. Disconnect the primary brake tube at the HCU (Figure 4).
6. Remove the primary brake tube from the vehicle.
CAUTION:
Use extreme care not to allow brake fluid to spill while removing the brake tube.
7. Discard the old brake tube.
8. Place the new primary brake tube into position.
9. Connect the primary brake tube nut to the HCU. Hand tighten the tube nut.
10. Connect the primary brake tube nut to the master cylinder. Hand tighten the tube nut.
11. Tighten the primary brake tube nut at the master cylinder to 170 in.lbs (19 N.m).
12. Connect the brake fluid level switch at the brake fluid reservoir.
13. Tighten the primary brake tube nut at the HCU until snug.
14. Remove the brake pedal prop rod.
15. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 3 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the primary HCU brake tube nut 1/4 turn for two seconds and then retighten the tube nut.
16. After the primary circuit has been bled, tighten the HCU brake tube nut to 170 in. lbs. (19 N.m).
17. Check brake fluid level and add DOT 3 brake fluid as required.
18. Verify that there are no brake fluid leaks and that the brakes operate properly.
19. Connect the negative battery cable.
E. KK (Jeep Liberty) Brake Tube Replacement
1. Open the hood and disconnect the negative battery cable.
2. Install a prop rod on the brake pedal to keep pressure on the brake system.
NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tube is being replaced. This will facilitate bleeding only the tubes from the master cylinder to the Hydraulic Control Unit (HCU).
3. Disconnect the brake fluid level switch at the brake fluid reservoir (Figure 5).
4. Disconnect the primary brake tube at the master cylinder (Figure 5).
5. Disconnect the primary brake tube at the HCU (Figure 5).
6. Remove the primary brake tube from the vehicle.
CAUTION:
Use extreme care not to allow brake fluid to spill while removing the brake tube.
7. Discard the old brake tube.
8. Place the new primary brake tube into position.
9. Connect the primary brake tube nut to the HCU. Hand tighten the tube nut.
10. Connect the primary brake tube nut to the master cylinder. Hand tighten the tube nut.
11. Tighten the primary brake tube nut at the master cylinder to 170 in. lbs. (19 N.m).
12. Connect the brake fluid level switch at the brake fluid reservoir.
13. Tighten the primary brake tube nut at the HCU until snug.
14. Remove the brake pedal prop rod.
15. Bleed the brake system using the following procedure:
a. Fill the master cylinder reservoir with DOT 3 brake fluid.
b. Have an assistant pump the brake pedal several times and then press and hold the brake pedal down.
c. While the assistant is holding the brake pedal down, loosen the primary HCU brake tube nut 1/4 turn for two seconds and then retighten the tube nut.
d. Repeat Steps 15a. through 15c. until all air is removed from the hydraulic circuit.
16. After the primary circuit has been bled, tighten the HCU brake tube nut to 170 in. lbs. (19 N.m).
17. Check brake fluid level and add DOT 3 brake fluid as required.
18. Verify that there are no brake fluid leaks and that the brakes operate properly.
19. Connect the negative battery cable.