Ram Truck 1500, 2500 & 3500 (2006-2008)

Power Brake Booster

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Removal & Installation



Except Hydro-Boost
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove master cylinder.
  4.  
  5. Disconnect vacuum line at booster.
  6.  
  7. Remove clip securing booster push rod to brake pedal.
  8.  
  9. Remove the nuts from the booster mounting studs.
  10.  
  11. Remove the booster and gasket from front cowl panel.

    Click image to see an enlarged view

    Fig. Vacuum brake booster removal

  12.  

To install:

  1. Guide the booster studs into the cowl panel holes and seat the booster on the panel .
  2.  
  3. Install and tighten new booster attaching nuts to 250 inch lbs. (28 Nm).
  4.  
  5. Install the booster push rod on brake pedal and install clip.
  6.  
  7. Install the booster check valve if removed and connect the vacuum hose to the check valve.
  8.  
  9. Install the master cylinder.
  10.  
  11. Fill and bleed the brake system.
  12.  

Hydro-Boost

NOTE
If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With engine off depress the brake pedal 5 times to discharge the accumulator.
  4.  
  5. Remove brake lines from master cylinder.
  6.  
  7. Remove mounting nuts from the master cylinder.
  8.  
  9. Remove the master cylinder.
  10.  
  11. Remove the return hose and the two pressure lines from the hydraulic booster.

    Click image to see an enlarged view

    Fig. Pressure lines and related parts

  12.  
  13. From inside the vehicle remove the booster push rod clip, washer and rod remove from the brake pedal.
  14.  
  15. Remove the mounting nuts from the hydraulic booster and remove the booster.
  16.  

To install:

  1. Install the hydraulic booster and tighten the mounting nuts to 21 ft. lbs. (28 Nm).
  2.  
  3. Install the booster push rod, washer and clip onto the brake pedal.
  4.  
  5. Install the master cylinder on the mounting studs. and tighten the mounting nuts to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the brake lines to the master cylinder and tighten to 170 inch lbs. (19 Nm).
  8.  
  9. Install the hydraulic booster pressure lines to the booster.
  10.  
  11. Tighten the pressure lines to 30 ft. lbs. (41 Nm).
    NOTE
    Inspect O-rings on the pressure line fittings to insure they are in good condition before installation. Replace O-rings if necessary.

  12.  
  13. Install the return hose to the booster.
  14.  
  15. Bleed base brake system.
  16.  
  17. Fill the power steering pump with fluid. Bleed hydraulic booster.
    WARNING
    MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.

  18.  

The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air.

Bleed hydraulic booster as follows:

  1. Fill power steering pump reservoir.
  2.  
  3. Disconnect fuel shutdown relay or harness and crank the engine for several seconds.
  4.  
  5. Check fluid level and add if necessary.
  6.  
  7. Connect fuel shutdown relay or harness and start the engine.
  8.  
  9. Turn the steering wheel slowly from lock to lock twice.
  10.  
  11. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times.
  12.  
  13. Start the engine and turn the steering wheel slowly from lock to lock twice.
  14.  
  15. Turn off the engine and check fluid level and add if necessary.
    NOTE
    If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8.

  16.  

 
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