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Booster - Power Brake: Removal: 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.
  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)
  4. Remove master cylinder. (Refer to BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - REMOVAL) 
    Fig 2: Identifying Master Cylinder Wiring Harness & Connectors
    GC0014393Courtesy of DAIMLERCHRYSLER CORP.
  5. If equipped with MK25 and Electronic Stability Program (ESP), disconnect wiring harness (6) connector at pedal travel sensor (7) on power brake booster (3).
  6. If equipped with MK25 and ESP, disconnect wiring harness (6) connector at active brake booster solenoid (4).
    Fig 3: Vacuum Hose Connection
    GC0014403Courtesy of DAIMLERCHRYSLER CORP.
  7. Disconnect vacuum hose (3) from check valve (2) on face of booster (1). Do not remove check valve from booster. 
    Fig 4: Locating Stop Lamp Switch and Pedal Rod
    GC0014396Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove brake lamp switch. (Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL)
  9. Remove booster push rod from pin on brake pedal. To do so:
    • Position small screwdriver between center tang on power brake booster brake pedal pin retaining clip (3).
    • Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin, then slide retaining clip off brake pedal pin.
    • Discard retaining clip (3). It is not to be reused. Install NEW retaining clip when assembling. 
  10. Slide booster push rod (5) off brake pedal pin (4).
    Fig 5: Booster and Pedal Mounting
    GC0014402Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove four power brake booster mounting nuts (4).
  12. Slide power brake booster forward out of dash panel and remove through opening between cross-brace and windshield.
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