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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.
  1. Move driver's seat to full rearward position.
    Fig 1: Disconnecting/Connecting Battery Cables
    GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  2. Disconnect and isolate battery negative cable (2) from battery post.
  3. Remove windshield wiper module. (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL)
    Fig 2: Brake Master Cylinder And Fluid Level Sensor Connection
    GC0014351Courtesy of DAIMLERCHRYSLER CORP.
  4. Disconnect wiring harness connector (4) from brake fluid level sensor (2) in master cylinder brake fluid reservoir (1).
    Fig 3: Brake Tubes At Master Cylinder
    GC0014392Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove primary (3) and secondary (2) brake tubes from master cylinder (4). Install sealing plugs in open brake tube outlet ports.
    Fig 4: Master Cylinder Mounting Nuts
    GC0039414Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Before removing master cylinder from power brake vacuum booster, master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into power brake vacuum booster. Use only Mopar® Brake Parts Cleaner or equivalent.
  6. Remove two nuts (2) attaching master cylinder (3) to power brake booster (1).
  7. Slide master cylinder (3) straight out of power brake booster (1).
    Fig 5: VACUUM HOSE CONNECTION - RHD
    GC0039421Courtesy of DAIMLERCHRYSLER CORP.
  8. Disconnect vacuum hose (1) from check valve on face of booster (2). Do not remove check valve from booster. 
  9. Remove driver side silencer under instrument panel. (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - INSTALLATION)
  10. Remove steering column opening cover. (Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION)
    Fig 6: STOP LAMP SWITCH MOUNTING - RHD
    GC0039419Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove stop lamp switch (2). (Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL)
    Fig 7: View Of Pedal Retaining Clip
    GC0039420Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When removing booster push rod from brake pedal pin, be careful not to damage rubber O-ring on pin.
  12. Remove booster push rod from pin on brake pedal. To do so:
    • Position small screwdriver (1) between center tang on power brake booster brake pedal pin retaining clip (4).
    • Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin (3), then slide retaining clip off brake pedal pin.
    • Discard retaining clip. It is not to be reused. Install NEW retaining clip when assembling. 
  13. Slide booster push rod (2) off brake pedal pin (3).
    Fig 8: BOOSTER AND PEDAL MOUNTING - RHD
    GC0039418Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove four power brake booster mounting nuts (5).
  15. Slide power brake booster forward out of dash panel and remove through opening between cross-brace and windshield.
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