Booster, Power Brake: Installation: Left-Hand-Drive

WARNING: This page is about a different car, the 2014 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Booster Seal

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NOTE:

Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Fig 2: Pedal And Booster Mounting - LHD

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Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position.
Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step.

Fig 3: Mounting Nut Torque Sequence
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CAUTION:
Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.
Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).

Fig 4: Brake Pedal Clip
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Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1).
Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.

Fig 5: Identifying Stop Lamp Switch & Pedal Clip
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CAUTION:
Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008.
Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to SWITCH, STOP LAMP, INSTALLATION .
If equipped, install the silencer pad below the instrument panel.

Fig 6: Identifying Vacuum Hose & Check Valve
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CAUTION:
When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces.
Connect the vacuum hose (2) to the vacuum check valve (1).

Fig 7: Rear Brake Tubes At Junction Block
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Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 N.m (150 in. lbs.).
Install the master cylinder. Refer to MASTER CYLINDER, BRAKE, INSTALLATION .

Fig 8: Wheelhouse Brace
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Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Fig 9: Cowl Screen
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Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place.
Install the wiper arms. Refer to ARM, WIPER, INSTALLATION .

Fig 10: Cowl Top Screen
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Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2).
Connect the battery negative cable to its post on the battery.
Bleed the base brake system. Refer to STANDARD PROCEDURE .
Road test the vehicle to ensure proper operation of the brakes.