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Vacuum Booster (1999-2001): Removal

CAUTION: Reserve vacuum in vacuum booster must be pumped down (removed) before removing master cylinder from vacuum booster. This is necessary to prevent vacuum 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.
  1. With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes). Remove primary and secondary brake tubes from master cylinder outlet ports. See Figure . Install plugs in master cylinder outlet ports.
    CAUTION: Before removing master cylinder from vacuum booster, master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt from falling into vacuum booster.
  2. Clean area where master cylinder attaches to vacuum booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Remove 2 nuts, attaching master cylinder to vacuum booster. See Figure . Remove master cylinder from vacuum booster. Remove 2 structural support struts from bracket above vacuum booster. Loosen bolts on other ends of structural support struts and move struts aside. Remove vacuum hose from vacuum port on intake manifold and check valve on vacuum booster.

    DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER.

    NOTE: Removal of knee blocker trim panel makes access to brake pedal and vacuum booster mounting nuts easier. See Figure .
  3. Remove steering column knee blocker trim panel from instrument panel. Locate vacuum booster input rod to brake pedal connection under instrument panel. Position a small screwdriver between center tang on power brake booster input rod to brake pedal pin retaining clip. See Figure .
  4. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. Remove 2 nuts on right hand side mounting wiring harness junction connector bracket to vacuum booster studs.
  5. Remove 4 nuts attaching vacuum booster to dash panel. Nuts are accessible from under dash panel in area of steering column and pedal bracket. From outside vehicle, slide vacuum booster forward until mounting studs clear dash panel. Then tilt vacuum booster up and toward engine to remove.
CAUTION: DO NOT attempt to disassemble power brake vacuum booster it is to be serviced ONLY as a complete assembly.
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