Operation CHARM: Car repair manuals for everyone.

Removal

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

1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes).
2. Remove both battery cables from battery.
3. Remove the battery thermal guard and the battery from the battery tray.

Air Inlet Resonator:





4. Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner housing.
5. If vehicle is equipped with speed control, unplug wiring harness connector from the speed control servo. Then disconnect vacuum lines from the speed control servo and vacuum reservoir on battery tray.
6. Remove bolt attaching the speed control servo bracket to the battery tray. Slide the bracket forward to unhook it from the battery tray and remove.

Battery Tray Mounting Locations:





7. Remove the 2 bolts and the nut attaching the battery tray to the body of the vehicle.

Electrical Connection To Fluid Level Sensor:





8. Remove wiring harness connector from brake fluid level sensor in master cylinder fluid reservoir.
9. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent.

Master Cylinder Attachment To Power Brake Vacuum Booster:





10. Remove clip attaching drain hose to brake tube at master cylinder. Remove drain hose from wiper module. Remove the 2 nuts attaching the master cylinder assembly to the power brake vacuum booster.

NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the power brake vacuum booster.

11. Remove the master cylinder and the brake tubes as an assembly from power brake vacuum booster. When master cylinder is removed, lay it out of the way on top of the left motor mount.
12. Disconnect vacuum hose from check valve located on power brake vacuum booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER.

Booster Input Rod Retaining Pin:





13. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip.
14. 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 assembled.
15. Remove the 4 nuts attaching the vacuum booster to the dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly.
16. From outside the vehicle, slide power brake vacuum booster forward until its mounting studs clear dash panel. Then tilt the booster up and toward the center of vehicle to remove.

CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly.