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Power Brake Booster: Installation

WARNING: This page is about a different car, the 2002 Dodge Intrepid, 2002 Chrysler Intrepid, 2002 Chrysler Concorde, and 2002 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position power brake vacuum booster on dash panel.
  2. Install and tighten the 4 power brake booster to dash panel mounting nuts. See TORQUE SPECIFICATIONS  .
  3. Using Lubriplate or equivalent, coat the bearing surface of brake pedal pin.
    4. CAUTION: DO NOT use the old retaining clip. Use only a NEW retainer clip.
  4. Connect the booster input rod to brake pedal pin and install a NEW retainer clip.
    5. NOTE: Before installing master cylinder, reposition under hood wiring harness above master cylinder mounting studs, in front of booster. See Figure .
  5. Carefully position master cylinder on booster. Position wire harness routing bracket onto right master cylinder mounting stud.
  6. Install and tighten the 2 master cylinder-to-power brake booster mounting nuts. See TORQUE SPECIFICATIONS  .
  7. Reconnect brake fluid level switch connector.
  8. Connect all vacuum hoses onto the booster vacuum check valve.
  9. Check brake lamp operation.
  10. Install the wiper module reinforcement on the vehicle. See Figure . Install the 8 bolts, attaching the reinforcement to the strut towers. Install the bolt attaching the wiper module to the reinforcement.
  11. Install the covers over the wiper module and the cowl. See Figure . Install and securely tighten the attaching screws.
  12. Reconnect the battery ground cable to the ground stud on the right strut tower.
  13. Turn windshield wipers ON, then OFF, in order to park wipers on the proper position before installing wiper arms.
  14. Install the wiper arms on the pivots. See Figure . Install and securely tighten the wiper arm to pivot attaching nuts. Install the caps on the wiper arms covering the pivot nuts.
  15. Verify proper operation of the power brake booster and brake system.
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