Power Brake Booster: Installation
- Position the power brake booster onto the dash panel. It may be necessary to push in on booster input rod as it is guided through the dash panel. Install the four nuts mounting the booster to the dash panel. SeeFigure and Figure . Tighten the mounting nuts to specification. See TORQUE SPECIFICATIONS .
- Using Mopar® Lubricate or equivalent, coat the surface of the brake pedal pin where it contacts the booster input rod. Install the booster input rod on the brake pedal pin and install a NEW retaining clip. See Fig 1.
- Replace the stoplight switch. See STOPLIGHT SWITCH .
- Install the silencer panel below the steering column. Connect vacuum hose to check valve on power brake booster.
- Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. See Figure. Install a NEW vacuum seal on rear mounting flange of the master cylinder. Position the master cylinder on to the studs of the booster, aligning the push rod on the booster with the master cylinder piston. Install the two nuts mounting the master cylinder to the booster. See Figure. Tighten both master cylinder mounting nuts to specification. See TORQUE SPECIFICATIONS .
- Connect the wiring harness connector to brake fluid level switch in the master cylinder fluid reservoir. Connect primary and secondary brakelines to non-ABS junction block. See Figure. Tighten brakeline nuts to specification.
- To install, position the wiper module into the cowling. Install the bolts that secure the wiper module to the dash. See Figure. Install the nuts that retain the wiper module. Connect the drain tubes to the nipples on the wiper module. Connect the windshield washer tube. Connect the wire harness connector to the wiper module. Connect the positive lock on the wiper module wire connector. See Figure.
- When installing the cowl grille over the wiper module, make sure that the fore/aft locator on the underside of cowl grille, seats into the locator grooves on top of wiper module. Make sure the washer hose is properly routed and not pinched. Center the cowl grille to the body and windshield. Make sure the "arrow" indicator head of the quarter-turn fasteners are pointing towards the windshield. Use star sequence when tightening all cowl grille mounting screws by hand.
- Install the wiper arms. Check for proper spray pattern from the washer nozzles.
- On models equipped with cruise control, install cruise control servo and tighten the mounting nuts to specification. See TORQUE SPECIFICATIONS .
- On all models, install the battery tray. Install the two nuts and one bolt attaching the battery tray to the vehicle.
- On models equipped with cruise control, connect the servo vacuum hose to the vacuum tank on the battery tray. Connect cruise control servo wiring connector. On all models, install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing. Securely tighten hose clamp at air cleaner housing and throttle body.
- Secure the engine coolant filler neck to the battery tray with its mounting screw. Install the battery clamp and mounting nut. Install the positive and negative battery cables. Bleed the brakes as necessary. See BLEEDING BRAKE SYSTEM .
- Road test vehicle.
CAUTION:
When installing the brake pedal pin on the power brake booster input rod, use a NEW retaining clip.
CAUTION:
DO NOT reuse the original stoplight switch. The switch can only be adjusted once. If the switch is not adjusted properly or has been removed for some service, a NEW switch must be installed and adjusted.
CAUTION:
A seal on the rear of the master cylinder, is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the power brake booster.
CAUTION:
When removing the vacuum seal from the master cylinder do not use a sharp tool.
CAUTION:
Do not allow wiper module to rest on brake master cylinder reservoir. Damage to brake system can result.