Installation

PROCEDURE
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 in. 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.
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. Refer to Antilock Brake System Hydraulic Control Unit Service and Repair.

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.

CAUTION: 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 in only using Mopar Dielectric Grease-And No Substitutes.

Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS:

Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS:

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 Service and Repair Removal.

9. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod.
10. Install the 2 master cylinder mounting nuts and torque to 28 Nm (250 in. lbs.) torque.

Primary And Secondary Brake Tubes Without ABS Brakes:

Bleeding Tubes Attached To Non-ABS Master Cylinder:

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