OEM 2005 Chrysler PT Cruiser Brake Booster

2005 Chrysler PT Cruiser Brake Booster Parts and Q&A

• Q: How to Service and Repair a Brake Booster on a Right-Hand Drive on 2005 Chrysler PT Cruiser?

  A: The entire process starts by disconnecting the negative cable and blocking access to the battery. Take the refrigerant out of the system using a recovery machine, then break the lines at their midline connection block and place them above the engine torque strut so they do not touch anything. Pull the master cylinder out first and after that, inside the car, remove the silencer beneath the knee blocker and tuck the knee blocker down. The brake pedal-to-power brake booster input rod connection can be found under the instrument panel; rotate the retaining clip tang with a little screwdriver, remove the clip, discard it and ensure you are using a new clip when you reinstall. Get rid of the four nuts holding the brake booster to the power panel found under the panel and near the bracket of the brake pedal. Slide the booster forward just enough to take out the bolts behind the panel and finally remove it from the engine compartment. During installation, fit the brake booster onto the dash panel so that the dash seal is over the booster studs and tighten its four mounting nuts to a torque of 34 Nm (25 ft. lbs.). Add Lubriplate or its equivalent to the surface of the brake pedal pin, hook the brake booster input rod on the pin and use a new retaining clip. In the process, replace the brake switch, make sure to discard the old one and then put back the knee blocker and silencer pad. Unscrew the tops of the refrigerant lines, set them together and make sure the sealing O-rings are well lubricated with PAG oil, smooth and tear-free. Tighten the retaining fastener to 40 inch lbs, use an R-134a recovery machine for the refrigerant, reconnect the negative cable on the battery and finish up the job. Apply the brake and check that it responds before driving and test the brake on the road to ensure it is working well.