LEMON Manuals: Even more car manuals for everyone
Home >> Dodge and Ram >> 2003 >> SX R/T >> Repair and Diagnosis >> Brakes >> Parking Brake System >> Disc Brakes & Drum Brakes >> Removal & Installation >> Power Brake Booster >> Installation

Power Brake Booster: Installation

  1. Turn the power brake booster sideways, then install it into the engine compartment down past the heater hoses and the strut tower. Rotate the booster so its 4 mounting studs and input rod are pointed straight toward the instrument panel. Slide the input rod and studs through the instrument panel and into mounting position.
  2. Under the instrument panel, install the 4 power brake booster mounting nuts. Tighten the nuts to specification. See TORQUE SPECIFICATIONS .
  3. Using Lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the brake booster input rod.
  4. CAUTION: Use only a new brake booster input rod-to-brake pedal retaining clip to ensure proper retainment.
    CAUTION: Install a new brake lamp switch any time the old switch is removed, or the brake booster or pedals have been changed or removed.
  5. Connect the power brake booster input rod-to-brake pedal pin. Install a new retaining clip. DO NOT use the old clip.
  6. Install and adjust a new brake lamp switch.
  7. Connect all previously removed vacuum hoses to the vacuum check valve.
  8. If the vehicle is equipped with ABS, install the ICU mounting bracket on the frame rail using its 3 bolts. Tighten the nuts to specification. See TORQUE SPECIFICATIONS .
  9. Connect the clutch pedal push rod. Slide the push rod on the clutch pedal mounted stud until the plastic retention clip locks it in place.
  10. Install the coolant reservoir. Tighten the retaining bolts to specification. See TORQUE SPECIFICATIONS . Connect the coolant overflow hose on the thermostat housing.
  11. Install the heater core coolant supply tube support bracket bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  12. Install the battery and battery tray in the vehicle.
  13. Install the air cleaner assembly.
  14. Install the master cylinder on the vehicle.
  15. Fill the brake fluid reservoir to specification.
  16. WARNING: Be certain a firm brake pedal is achieved before attempting to move the vehicle.
  17. Bleed the air from the brake hydraulic system. See BLEEDING BRAKE SYSTEM .