OEM 2002 Dodge Neon Brake Booster

2002 Dodge Neon Brake Booster Parts and Q&A

• Q: How to Service and Repair a Brake Booster on a Right-Hand Drive on 2002 Dodge Neon?

  A: The first step for vacuum brake booster repair is to separate the battery cable from the car and strongly pump the brake pedal to get the air from the brake booster to prevent contamination while removing the master cylinder. Remove the master cylinder, air cleaner assembly, battery and battery tray and then take off the bolts holding the heater core coolant supply tube support bracket. After that, undo the two reservoir bolts holding the reservoir on the panel, detach the coolant overflow hose and get rid of the coolant reservoir. From under the instrument panel, take out the retaining clip from the brake pedal push rod and pull it off the pin. If the clutch pedal push rod is used, press the plastic hold-down clip and remove the stud. Twist the clutch master cylinder so the retaining boss fits with the slot in the brake pedal support bracket and remove the four nuts holding the brake booster. Inside the engine, unbolt the two clutch fluid reservoir holds and gently remove the clutch master cylinder, putting the reservoir and line away from the engine compartment. Get the brake booster out by pulling it forward, rotating it and sliding it between the engine and dash panel, so it sits under the heater core coolant supply hoses. For installation, take the three screws out and slide your brake booster under the plenum that is on the battery tray side, after fixing it on the dash panel. Slide the vacuum supply hose back on the booster check valve and make sure it is completely seated. If called for, put the clutch master cylinder through the dash panel and stiffen the clutch fluid reservoir bolts to 7 Nm (62 in. lbs.). Both underneath the instrument panel, install and tighten the brake booster's retaining nuts to 34 Nm (25 ft. lbs.). Rub a little grease on the brake pedal pin and slide the brake booster push rod onto it. Hold it in place with the retaining clip. If necessary, line up the retaining boss of the clutch master cylinder with the brake pedal support bracket and rotate it by 90° to get it locked. Attach the clutch pedal push rod securely so it doesn't move. Fix the coolant reservoir in place, tighten the bolts to 7 Nm (62 in. lbs.) and join the hose that holds the overflow of coolant. Attach the heater core coolant supply tube support bracket bolts and tighten them to 36 Nm (27 ft. lbs.). Put the battery and battery tray into the vehicle next and then move on to install the air cleaner assembly and master cylinder. Top off the brake fluid reserve to the right level and bleed the braking system, so the brake pedal is firm before you can move the vehicle.