Installation

1. Position power brake booster onto dash panel.

Power Brake Booster Mounting:

2. Install and torque the 4 power brake vacuum booster mounting nuts to 29 Nm (250 inch lbs.) torque.
3. Using Lubriplate, or equivalent, coat the surface of the brake pedal pin where it contacts the brake vacuum booster input rod.
4. Connect power brake vacuum booster input rod to brake pedal pin and install a NEW retaining clip. Use only a new retainer clip DO NOT USE the old clip.

Power Brake Vacuum Booster Check Valve:

5. Connect all previously removed vacuum hoses onto power brake vacuum booster check valve.
6. If vehicle is equipped with ABS, install Hydraulic Control Unit (HCU).

CAUTION:
- When replacing the power brake vacuum booster on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. If old vacuum seal came out with master cylinder when it was removed from power brake vacuum booster, be sure it is removed from master cylinder before attempting to install master cylinder into power brake vacuum booster.

- When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod.

Lubricating Master Cylinder Push Rod:

7. Lubricate master cylinder push rod as indicated only using Mopar Dielectric Grease And No Substitutes. Refer to the Mopar Chemicals Catalog to obtain the required lubricant.

Installing Vacuum Seal On Master Cylinder Push Rod:

Vacuum Seal Positioned For Installing Master Cylinder:

8. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster.

CAUTION: If vehicle is equipped with ABS, be sure the old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Master Cylinder Removal for required vacuum seal removal procedure.

9. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod.

Master Cylinder Mounting To Vacuum Booster:

10. Install the 2 master cylinder mounting nuts and torque to 28 Nm (250 inch lbs.) torque.

Primary And Secondary Brake Tubes W/O ABS Brakes:

Primary And Secondary Brake Tubes With ABS Brakes:

11. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.) torque.
12. Reconnect wiring connector to fluid level sensor.
13. Adjust stop lamp switch as necessary.
14. Bleed brake system.