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Power Brake Booster: Removal

  1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 pumps). Disconnect negative and positive battery cables. Remove battery thermal guard shield. Remove battery clamp, nut and battery from the battery tray. Remove screw securing engine coolant filler tube to battery tray.
  2. On models equipped with cruise control, disconnect the vacuum hose at the vacuum tank built into the battery tray. On all models, remove the two nuts and one bolt securing battery tray in place. Remove battery tray.
  3. Remove the air inlet resonator and hoses as an assembly from the throttle body. Remove the air cleaner assembly.
  4. On models equipped with cruise control, disconnect wiring harness connector from the speed control servo. Remove the two servo bracket mounting nuts. Lay speed control servo aside with bracket attached.
  5. On all models, remove the wiper arms. Remove the 4 screws securing the cowl grille to wiper module. See Fig 1. Unlock the quarterturn fasteners at the outboard ends of the cowl grille from the body.
    6. CAUTION: To prevent the hood from getting scratched before the removal of the cowl grille, cover the outboard exterior ends of the cowl grille with masking tape as necessary.
    NOTE: DO NOT excessively bend the cowl grille during removal. Bend the cowl grille just enough to clear the top of the wiper pivot shaft and the bottom rear corner of the hood.
  6. Remove the cowl grille by raising it above the (driver's side) wiper pivot shaft and swinging it away towards the engine compartment. The cowl grille will need to be bent on outboard end to simultaneously clear the top of the wiper pivot shaft and the bottom corner of the hood. Close the hood, but DO NOT latch. Remove the outboard screws. See Fig 2.
  7. Disconnect the washer hose in-line connector. Disconnect the washer hose and grommet from the hole in the wiper module and pull it out. Raise the cowl grille over the opposite wiper pivot shaft while moving it away from the vehicle. Remove cowl cover from vehicle and set aside.
  8. Disconnect the positive lock on the wiper module wire connector. See Fig 3. Disconnect the wiper module wire connector from the engine compartment wire harness.
  9. Disconnect the windshield washer hose from the coupling outside the module. Disconnect the drain tubes from the nipples on the bottom of the wiper module. Remove nuts holding the wiper module to the lower windshield fence. See Fig 4. Remove bolts holding the wiper module to the dash panel.
    10. CAUTION: DO NOT allow the wiper module to rest on the brake master cylinder reservoir. Damage to the brake system can result.
  10. Lift the wiper module from the weld-studs on the lower windshield fence. Remove wiper module and set aside.
  11. Disconnect wiring harness connector from brake fluid level switch in master cylinder fluid reservoir. See Figure.
    12. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster.
  12. Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopar® Brake Parts Cleaner or equivalent.
  13. Disconnect primary and secondary brakelines downstream of the master cylinder to allow the master cylinder to be moved aside. Install sealing plugs in the now open brakeline ports and install caps on ends of tubes.
    14. NOTE: It is not necessary to remove the brakelines from the master cylinder when removing the master cylinder from the vacuum booster.
  14. Remove two nuts attaching master cylinder to power brake booster. See Figure.
  15. Slide master cylinder straight out of power brake booster. Remove master cylinder with primary and secondary brakelines from vehicle.
    16. 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 whenever the master cylinder is removed from the power brake vacuum booster. See Figure.
  16. Disconnect the vacuum hose from the check valve located on the vacuum booster. DO NOT remove the check valve from the power brake booster.
  17. Inside vehicle, remove the silencer panel under the instrument panel below the steering column. Locate the booster input rod to brake pedal connection under the instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. Rotate the screwdriver enough to allow the retaining clip center tang to pass over the end of the brake pedal pin. Pull the retaining clip off the brake pedal pin. Discard the retaining clip and use a NEW clip upon installation. See Fig 5.
    18. CAUTION: DO NOT attempt to disassemble the power brake vacuum booster. It is serviced only as a complete assembly.
  18. Slide the booster input rod off the pedal pin. Remove the four nuts attaching the power brake booster to the dash panel. Slide the power brake booster forward and remove through the engine compartment. See Fig 6 and Fig 7 .
Fig 1: Removing/Installing Cowl Grille (1 Of 2)
G00200980Courtesy of CHRYSLER CORP.
Fig 2: Removing/Installing Cowl Grille (2 Of 2)
G00200981Courtesy of CHRYSLER CORP.
Fig 3: Removing/Installing Wiper Module (1 Of 2)
G00200983Courtesy of CHRYSLER CORP.
Fig 4: Removing/Installing Wiper Module (2 Of 2)
G00200982Courtesy of CHRYSLER CORP.
Fig 5: Removing/Installing Power Brake Booster (1 Of 3)
G00200984Courtesy of CHRYSLER CORP.
Fig 6: Removing/Installing Power Brake Booster (2 Of 3)
G00200985Courtesy of CHRYSLER CORP.
Fig 7: Removing/Installing Power Brake Booster (3 Of 3)
G00200986Courtesy of CHRYSLER CORP.
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