RHD
REMOVAL - RHDNOTE: Before proceeding, Refer to BRAKES WARNING.
1. Disconnect the negative (ground) cable from the battery and isolate cable.
2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the HCU.
3. Raise vehicle.
4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket (Fig. 24).
CAUTION: Do not apply a 12 volt power source to any terminals of the HCU connector when disconnected.
5. Remove the 24-way connector (Fig. 24) from the CAB. The 24-way connector is removed from the CAB using the following procedure. Grasp the lock on the 24-way connector (Fig. 24) and pull it as far out as possible (Fig. 25). This will raise and unlock the 24-way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes.
6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU.
7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. (Fig. 26).
8. Remove the 3 bolts (Fig. 27) attaching the ICU mounting bracket to the front suspension crossmember.
9. Remove ICU and the mounting bracket as a unit from the vehicle.
10. Remove the 3 bolts (Fig. 28) mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket.
11. For the procedure on separating and attaching the CAB to the HCU, refer to DISASSEMBLY.
INSTALLATION - RHD
1. Install the ICU on the mounting bracket (Fig. 28). Install the 3 bolts (Fig. 28) attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.).
CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember.
2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember (Fig. 27). Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to (Fig. 26) for the correct chassis brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket.
3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown in (Fig. 26). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.).
NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector.
4. Install the 24-way connector (Fig. 24) on the CAB using the following procedure. Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock (Fig. 25). This will pull the connector into the socket of the CAB and lock it in the installed position.
NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle.
5. Clip the cab wiring harness (Fig. 24) to the ICU mounting bracket.
6. Install the routing clips (Fig. 32) on the brake tubes.
7. Lower the vehicle.
8. Connect negative cable back on negative post of the battery.
9. Bleed the base and ABS hydraulic systems.
10. Road test vehicle to ensure proper operation of the base and antilock brake systems.