Sensor-Travel - MK25: Removal

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.

CAUTION: Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent power brake booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping brake pedal, with vehicle's engine not running, until a firm feeling brake pedal is achieved.

With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes).

Fig 1: Disconnecting/Connecting Battery Cables
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect and isolate battery negative cable (2) from battery post.

Fig 2: Identifying Master Cylinder Wiring Harness & Connectors
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect wiring harness (6) connector at pedal travel sensor (7) on power brake booster (3).

Fig 3: Travel Sensor Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Using a small screwdriver, remove sensor retaining ring (1).
Pull travel sensor straight out of booster.