Sensor-Travel - MK25: Installation

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: Installing O-Ring

Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Before installing new pedal travel sensor, replace O-ring (2) inside booster opening. Sparingly lubricate NEW O-ring with brake fluid. Use care not to lose O-ring inside booster.

Install NEW sensor retaining ring (1) in groove on booster.

Fig 2: Travel Sensor Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Align sensor keyway with notch in top of sensor mount on booster housing, then install pedal travel sensor (2). The sensor will snap into place past the retaining ring (1).

Fig 3: Identifying Master Cylinder Wiring Harness & Connectors
Courtesy of DAIMLERCHRYSLER CORP.
Connect wiring harness (6) connector to pedal travel sensor (7).

Fig 4: Disconnecting/Connecting Battery Cables
Courtesy of DAIMLERCHRYSLER CORP.
Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
Perform Verification Test and clear any faults. (Refer to BRAKES - DIAGNOSIS AND TESTING)
Start vehicle and check for vacuum leaks around sensor. Correct as necessary.