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Booster - RHD

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Booster Seal
GC0014404Courtesy of DAIMLERCHRYSLER CORP.
NOTE: Before installing booster, make sure there is a NEW booster seal (2) placed over push rod and mounting studs on rear of booster (1).
Fig 2: BOOSTER AND PEDAL MOUNTING - RHD
GC0039418Courtesy of DAIMLERCHRYSLER CORP.
  1. Install power brake booster through opening between cross-brace and windshield. Guide booster (2) push rod and mounting studs through dash panel (3).
    NOTE: Be sure to evenly tighten all four booster mounting nuts to specifications or a vacuum leak can result.
  2. Install four power brake booster mounting nuts (5). Tighten nuts to 25 N.m (18 ft. lbs.).
    CAUTION: When installing booster push rod on brake pedal pin, be careful not to damage rubber O-ring on pin.
  3. Slide booster push rod onto brake pedal pin. Install NEW retaining clip securing push rod to brake pedal.
    Fig 3: STOP LAMP SWITCH MOUNTING - RHD
    GC0039419Courtesy of DAIMLERCHRYSLER CORP.
  4. Install and adjust brake lamp switch (2). (Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION)
  5. Install steering column opening cover. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION)
  6. Install driver side silencer under instrument panel. (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - INSTALLATION)
    Fig 4: VACUUM HOSE CONNECTION - RHD
    GC0039421Courtesy of DAIMLERCHRYSLER CORP.
  7. Connect vacuum hose (1) to check valve on face of booster (2). Do not remove check valve from booster. 
    Fig 5: VACUUM SEAL ON REAR OF MASTER CYLINDER
    GC0039413Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When replacing master cylinder on vehicle, a NEW vacuum seal (2) MUST be installed on master cylinder.
  8. Install NEW vacuum seal (1) on rear of master cylinder (2) making sure seal fits squarely in mounting groove.
    Fig 6: Master Cylinder Mounting Nuts
    GC0039414Courtesy of DAIMLERCHRYSLER CORP.
  9. Position master cylinder (3) on studs of power brake booster, aligning booster push rod with master cylinder piston.
  10. Install two master cylinder mounting nuts (1). Tighten mounting nuts to 15 N.m (133 in. lbs.).
    Fig 7: Brake Tubes At Master Cylinder
    GC0014392Courtesy of DAIMLERCHRYSLER CORP.
  11. Thread primary (3) and secondary (2) brake tubes into master cylinder primary and secondary ports. Tighten tube nuts to 20 N.m (177 in. lbs.).
    Fig 8: Brake Master Cylinder And Fluid Level Sensor Connection
    GC0014351Courtesy of DAIMLERCHRYSLER CORP.
  12. Connect wiring harness connector (4) to brake fluid level sensor (2) mounted in brake fluid reservoir (1).
  13. Install windshield wiper module and components removed to access. (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION)
    Fig 9: Disconnecting/Connecting Battery Cables
    GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  14. Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
  15. Fill and bleed brakes as necessary.
  16. Road test vehicle to ensure proper operation of brakes.
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