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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> Brakes >> Parking Brake System >> Mechanical Brake System - Base (Service Information) >> Booster-Power Brake >> Installation >> RHD

Booster-Power Brake: Installation: RHD

Fig 1: Booster Seal
GC0014404Courtesy of DAIMLERCHRYSLER CORP.
NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.
  1. Install the power brake booster on the dash panel using the reverse of how it was removed. Slide the push rod and studs through the dash panel and into mounting position.
  2. Under the instrument panel, install the four power brake booster mounting nuts. Tighten the nuts to 34 N.m (25 ft. lbs.).
  3. Using Mopar® Lubriplate, or equivalent, coat the surface of the brake pedal pin where it contacts the brake booster push rod.
  4. Install the power brake booster push rod on the pin mounted on the side of the brake pedal. Install a NEW retaining clip (1) on the end of the pin. Do not reuse the old clip. 
    CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted.
    Fig 2: Adjustment Lever Movement
    GC0000132Courtesy of DAIMLERCHRYSLER CORP.
  5. Mount and adjust the NEW stop lamp switch using the following procedure:
    • Insert the plunger end of the switch in the mounting bracket by aligning the index tab on the switch with the slot in the mounting bracket.
    • When the switch is fully seated in the bracket, rotate the switch clockwise approximately 30° to lock the switch into place.
    • With the brake pedal in the fully released position, move the lever on the back of the stop lamp switch from the non-adjusted angle position to the full vertical position. This will permanently adjust the switch to the vehicle.
  6. Install the knee blocker.
  7. Install the silencer pad below the knee blocker.
    CAUTION: When installing the vacuum hoses onto the check valve, make sure the hoses are routed properly to avoid possible contact with the exhaust manifold and other unfriendly surfaces.
  8. Connect all previously removed vacuum hoses to the vacuum check valve.
  9. Install the master cylinder. (Refer to BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - INSTALLATION) 
  10. Remove the caps and connect refrigerant lines. Be certain the sealing O-rings are well lubricated with PAG oil.
  11. Using a refrigerant recovery machine, evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE in HVAC - SERVICE INFORMATION.
    Fig 3: Battery Cables
    GC0041103Courtesy of DAIMLERCHRYSLER CORP.
  12. Connect the battery negative cable (1) to its post on the battery (4).
    Fig 4: Air Cleaner Cover
    GC0021569Courtesy of DAIMLERCHRYSLER CORP.
  13. Install the air cleaner cover.
    WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle.
  14. Road test the vehicle to ensure proper operation of the brakes.
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