Power Brake Booster - Removal - RHD

BOOSTER - RHD

1. Move driver's seat to full rearward position.
2. Disconnect and isolate negative battery cable (1).
3. Remove windshield wiper module Wiper Arm Linkage - Removal.

4. Disconnect wiring harness connector (4) from brake fluid level sensor (2) in master cylinder brake fluid reservoir (1).

5. Remove primary (3) and secondary (2) brake tubes from master cylinder (4). Install sealing plugs in open brake tube outlet ports.

CAUTION: Before removing master cylinder from power brake vacuum booster, master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into power brake vacuum booster. Use only Mopar(R) Brake Parts Cleaner or equivalent.

6. Remove two nuts (2) attaching master cylinder (3) to power brake booster (1).
7. Slide master cylinder (3) straight out of power brake booster (1).

8. Disconnect vacuum hose (1) from check valve on face of booster (2). Do not remove check valve from booster.
9. Remove driver side silencer under instrument panel Silencer Panel - Installation.
10. Remove steering column opening cover Steering Column Opening Cover - Installation.

11. Remove stop lamp switch (2) Stop Lamp Switch - Removal.

CAUTION: When removing booster push rod from brake pedal pin, be careful not to damage rubber O-ring on pin.

12. Remove booster push rod from pin on brake pedal. To do so:
a. Position small screwdriver (1) between center tang on power brake booster brake pedal pin retaining clip (4).
b. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin (3), then slide retaining clip off brake pedal pin.
c. Discard retaining clip. It is not to be reused. Install NEW retaining clip when assembling.
13. Slide booster push rod (2) off brake pedal pin (3).

14. Remove four power brake booster mounting nuts (5).
15. Slide power brake booster forward out of dash panel and remove through opening between cross-brace and windshield.