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Removal

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: HCU Lines/Connector
GC0026825Courtesy of DAIMLERCHRYSLER CORP.
1 - MASTER CYLINDER
2 - ABM
3 - CHASSIS LINES
4 - HCU
5 - ELECTRICAL CONNECTOR
  1. Siphon the master cylinder.
  2. Remove the primary brake line at the master cylinder.
  3. Remove the primary brake line from the HCU (4).
  4. Remove the secondary brake line at the master cylinder.
  5. Remove the secondary brake line at the HCU (4).
  6. Remove the 4 chassis lines (3) at the HCU.
  7. Disconnect the HCU electrical connector (5).
    Fig 2: HCU/ABM
    GC0026826Courtesy of DAIMLERCHRYSLER CORP.
    1 - HCU
    2 - BRACKET
  8. Remove the 3 mounting nuts at the HCU bracket (2).
  9. Remove the HCU(1) with the bracket from the vehicle.
    Fig 3: Master Cylinder Mounted
    GC0026809Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER BRAKE BOOSTER
    2 - FLUID RESERVOIR
    3 - FLUID CAP
    4 - HCU CHASSIS LINES
    5 - HCU
    6 - MASTER CYLINDER
    7 - BRAKE LINES
    8 - FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
    9 - MOUNTING NUTS
    10 - VACUUM HOSE AND CHECK VALVE
  10. Disconnect the brake fluid level sensor electrical connector (8) from the fluid reservoir (2).
  11. Remove the 2 master cylinder mounting nuts (9).
  12. Remove the master cylinder (6).
  13. Disconnect vacuum hose at booster check valve (10).
    Fig 4: Left Hush Panel
    GC0026827Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove the hush panel (2).
    Fig 5: Column Access Cover
    GC0026817Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the steering column opening cover (2) and hush panel.
    Fig 6: Brake Booster Push Rod
    GC0026819Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOOSTER PUSH ROD
    2 - BRAKE PEDAL
  16. Remove retainer clip that holds booster push rod (1) on pedal pin (2). Then slide push rod off pin.
    Fig 7: Brake Booster Bolts
    GC0026818Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADJUSTABLE PEDALS MOTOR
    2 - STEERING COLUMN
    3 - BOOSTER MOUNTING NUTS
  17. Disconnect the brake lamp switch wire connector.
  18. Remove the brake lamp switch.
  19. Remove four nuts (3) that attach booster to dash panel.
    Fig 8: Electrical Wires
    GC0026823Courtesy of DAIMLERCHRYSLER CORP.
    1 - ELECTRICAL HARNESS
    2 - BRAKE BOOSTER
    3 - CLIP
  20. In the engine compartment, disconnect the wire harness routing clips (3) and move the harness (1) to the side and downward.
    Fig 9: Booster Removal/Install
    GC0026822Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRAKE BOOSTER
    2 - MOUNTING STUDS
  21. Remove the booster (1) from the vehicle.
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