Power Brake Booster - Installation

GAS ENGINE





NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.





1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position.
2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step.




CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.

3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).




4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1).
5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.




CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted.

6. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1). Installation
7. Install the steering column opening cover (and airbag if equipped) on the instrument panel. Steering Column Opening Cover - Installation




CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces.

8. Connect the vacuum hose (2) to the vacuum check valve (1).




9. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 Nm (150 in. lbs.).
10. Install the master cylinder. Master Cylinder - Installation




11. Install the powertrain control module (PCM). Powertrain Control Module - Installation
12. Connect the battery negative cable to its post on the battery.
13. Bleed the base brake system. Brake Bleeding
14. Road test the vehicle to ensure proper operation of the brakes.