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Booster - Power Brake: Installation: Booster

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
GC0014402Courtesy of DAIMLERCHRYSLER CORP.
  1. Install power brake booster through opening between cross-brace and windshield. Guide booster (1) push rod and mounting studs through dash panel (2).
    NOTE: Be sure to tighten all four booster mounting nuts to specifications or a vacuum leak can result.
  2. Install four power brake booster mounting nuts (4). Tighten nuts to 25 N.m (18 ft. lbs.) torque.
    Fig 3: Locating Stop Lamp Switch and Pedal Rod
    GC0014396Courtesy of DAIMLERCHRYSLER CORP.
  3. Slide booster push rod (5) onto brake pedal pin (4). Install NEW retaining clip (3) securing push rod to brake pedal.
  4. Install and adjust brake lamp switch (2). (Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION)
    Fig 4: Vacuum Hose Connection
    GC0014403Courtesy of DAIMLERCHRYSLER CORP.
  5. Connect vacuum hose (3) to check valve (2) on face of booster (1). Do not remove check valve from booster. 
    Fig 5: Identifying Master Cylinder Wiring Harness & Connectors
    GC0014393Courtesy of DAIMLERCHRYSLER CORP.
  6. If equipped with MK25 and Electronic Stability Program (ESP), connect wiring harness (6) connector at pedal travel sensor (7) on power brake booster (3).
  7. If equipped with MK25 and ESP, connect wiring harness (6) connector at active brake booster solenoid (4).
  8. Install master cylinder (1). (Refer to BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - INSTALLATION) 
  9. Install windshield wiper module and components removed to access. (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION)
    Fig 6: Disconnecting/Connecting Battery Cables
    GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  10. Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
  11. Fill and bleed brakes as necessary.
  12. Road test vehicle to ensure proper operation of brakes.
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