OEM 2005 Dodge Neon Brake Booster

2005 Dodge Neon Brake Booster Parts and Q&A

• Q: How to Remove and Install a Brake Booster in a Right-Hand Drive on 2005 Dodge Neon?

  A: The first thing to do when repairing the vacuum brake booster on a right-hand drive vehicle is to disconnect the battery cable and pump the brake pedal again and again so the system is empty when you take out the master cylinder. Unscrew the master cylinder, disassemble the air cleaner assembly, unhook the battery and remove the battery tray. After that, undo the heater core coolant supply tube support bracket bolts and both retaining bolts from the dash panel, separate the coolant overflow tube and take out the coolant reservoir. Underneath the dashboard, take out the clip holding the brake pedal push rod to the pin, then slide the push rod off the pin. If a tension rod is used on the clutch pedal, press the retention clip in to unfix it from the stud. Turn the clutch master cylinder until the retaining boss lines up with the hole in the brake pedal bracket, then take out all four retaining bolts from the brake booster. From inside the motor compartment, remove the screws that hold the reservoir in place and remove the clutch master cylinder by pulling it straight out and placing the reservoir and line assembly out of the way. Eliminate the brake booster by pulling it away from its holders, rotating it and bringing it down along the engine towards the foot of the dash panel, under the heater core coolant supply lines on the way. To install, remove the brake booster from the box, replace it on the dash panel by reversing the steps just taken, making sure it fits beneath the plenum next to the battery tray. Put the vacuum supply hose back on the booster check valve so that it is sitting correctly. If it fits, place the clutch master cylinder and the clutch fluid reservoir inside the dash panel and tighten the retaining bolts to 7 Nm (62 inch lbs.), assuming that's the standard. After removing the instrument panel, fit four retaining nuts to the brake booster bolts and fasten them securely at 34 Nm (25 ft. lbs.). Apply lubricant to the pin of the brake pedal, place the brake booster push rod on it and secure it with the retaining clip. Adjust and move the clutch master cylinder to lock it in place if that is necessary. Pull the release handle of the clutch pedal and securely attach the push rod by using the small retention clip. Set in place the coolant reservoir, tighten the bolts with torque of 7Nm (62 inch lbs.) and link the coolant overflow hose. Put the heater core coolant supply tube support bracket bolts back in and torque them to 36 Nm (27 ft. lbs.), after that, reinstall the battery and tray, air cleaner assembly and the master cylinder. Top off the brake fluid as needed and squeeze out the air, so you get a firm pedal before trying to drive the vehicle.