Chrysler Full-Size Vans 1989-1998 Repair Guide

Power Brake Booster

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: In-line mounted brake booster assembly



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Fig. Fig. 2: Transverse mounted brake booster assembly

  1. Remove the rear anti-lock valve, combination valve and master cylinder.
  2.  
  3. Disconnect the vacuum hose from the power booster.
  4.  
  5. On transverse mounted boosters, remove the pivot bolt, O-ring and nut that attach the booster rod to the bell crank.
  6.  
  7. On inline mounted boosters, remove the steering column knee bolster for access to the brake pedal. Remove the clip that attaches the pushrod and disconnect the pushrod from the brake pedal.
  8.  
  9. Remove the power booster attaching nuts and remove the booster.
  10.  

To install:
  1. Install the power booster and tighten to 11 ft.
  2.  

lbs. (23 Nm).

  1. On inline mounted boosters, connect the pushrod to the brake pedal and install the clip. From inside the vehicle, install the steering column knee bolster.
  2.  
  3. On transverse mounted boosters, install the pivot bolt, O-ring and nut that attach the booster rod to the bell crank. Coat the eyelet with Lubriplate® or equivalent prior to assembly. Tighten the pivot bolt to 30 ft. lbs. (40 Nm).
  4.  
  5. Connect the vacuum hose to the power booster.
  6.  
  7. Install the master cylinder, combination valve and rear anti-lock valve.
  8.  
  9. Refill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 3 or DOT 4 specifications. Properly bleed the brake system.
  10.  

 
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