OEM 2003 Dodge Neon Brake Booster

2003 Dodge Neon Brake Booster Parts and Q&A

• Q: How to Remove and Install a Brake Booster on a Right-Hand Drive on 2003 Dodge Neon?

  A: To get ready for repair, begin by disconnecting the negative battery cable, after that, pump the brake pedal several times to lower the pressure inside the power booster to avoid polluting the master cylinder while it is removed. Disconnect the master cylinder, the air cleaner assembly, the battery and the tray, then handle the bolts holding the heater core supply tube bracket. Following that, unscrew the two retaining bolts from the coolant reservoir below the dash, disconnect the coolant overflow tube from the thermostat and remove the coolant reservoir. Get underneath the instrument panel and take out the brake pedal push rod by removing its clip and sliding it completely off the pin. If it applies, press on the plastic retention clip and slide the clutch pedal push rod off the stud. Rotate the clutch master cylinder so that its retaining boss lines up with the brake pedal support bracket opening and remove the end nuts securing the brake booster. By opening the engine compartment, unbolt the two reservoir retaining bolts and lift the clutch master cylinder, placing the assembly outside the compartment. By holding back the brake booster with one hand and pulling straight up with the other, you can take it out, turn it and lower it below the heater core coolant hoses, getting it to the battery tray. For installation, first reverse the ways you took it out, so that the brake booster can be set under the plenum on the battery tray side and in between the engine and the dash panel. Set the vacuum supply hose on top of the booster check valve and make sure it is tight. If the master cylinder applies to your vehicle, set it inside the dash and tighten the reservoir bolts to 7 Nm (62 in. lbs.). Underneath the instrument panel, set the four brake booster retaining nuts and tighten them to 34 Nm (25 ft. lbs.). Coat the brake pedal pin with grease, put the brake booster push rod over the pin and attach it using the retaining clip. When necessary, slide the retaining boss into the hole in the brake pedal bracket until you can turn it 90 degrees to lock it in position. Lock the push rod onto the clutch pedal, so it stays in one position. Set the coolant reservoir into place, tighten the retaining bolts to 7 Nm (62 in. lbs.) and connect the coolant overflow hose. After installing the heater core coolant supply tube support bracket bolts and tightening them to 36 Nm (27 ft. lbs.), reassemble the battery and battery tray, air cleaner assembly and master cylinder. Put enough brake fluid in the reservoir and bleed out any remaining air from the brakes to make the pedal sensitive, prior to shifting the car.