2500 4x2 Pickup V8-5.9L VIN Z (1994)
Brake Bleeding: Service and Repair
Antilock Brake System Bleeding Procedures
Manual Bleeding
The content of this article reflects the changes called out by TSB 05-03-94.
ABS MANUAL BRAKE BLEEDING PROCEDURE
1. If master cylinder has been overhauled or a new cylinder will be installed, bleed cylinder on bench before installation. This shortens time needed
to bleed system and ensures proper cylinder operation.
2. If master cylinder was not serviced, wipe cylinder reservoir and filler caps clean with shop towels. Use Mopar brake cleaner if reservoir and caps
are extremely dirty. Then remove reservoir filler caps and fill reservoir with Mopar, or equivalent DOT 3 brake fluid.
3. Open all caliper and wheel cylinder bleed screws. Close bleed screws when fluid starts flowing from each bleed screw. Then top off master
cylinder reservoir again.
4. Bleed master cylinder first. Have helper operate brake pedal while bleeding each master cylinder fluid outlet line.
CAUTION: Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow additional air to be
drawn into the system. Check the cylinder fluid level frequently and add fluid as needed.
5. Bleed rear brake antilock valve next and combination valve afterward. Bleed each valve at brakeline fittings one at a time. Surround line fittings
with shop towels to catch fluid bled from valve.
6. There are two bleed procedures for the front antilock valve. If a new front valve is being installed, bleed the valve as described in procedure step
(7). However, if the original valve is still in the vehicle, bleed the valve as described in step (8).
7. If a new front antilock valve and motor assembly is being installed, bleed new valve as follows:
Fig. 23 Typical Fluid Container and Bleed Hose
a. Loosen bleed plug on new front valve about 1/4 to one full turn. Plug must be open to fully bleed upper and lower sections of front antilock
valve.