OEM 2009 Chrysler Aspen Brake Booster

2009 Chrysler Aspen Brake Booster Parts and Q&A

• Q: How to Service and Repair a Brake Booster with ESP on 2009 Chrysler Aspen?

  A: Install spacer block 3 and all the gaskets 2 in advance, if you have taken them out. Place the booster studs 2 through the holes in the cowl panel and place the booster on the panel. Place new booster bolts and tighten them to 28 Nm (250 in. lbs.). Attach the brake pedal to booster push rod 1 and clip it into place. Any time the original stop lamp switch has been disturbed or removed, you must install a replacement; do not adjust the old one. Make sure that output rod 3 of the brake booster is in the proper place and properly retained by an output rod retaining ring, as you can see from the master cylinder mounting hole. To let the master cylinder plunger sleeve receive the output rod, place the output rod in the middle and perpendicular to the master cylinder hole. Once you've removed the old booster, use a flashlight to make sure the shoulder and neck of the master cylinder are vacuum sealed; the integrity of the vacuum relies on a square seal hermetically sealing them. Ensure the plunger on the master cylinder is over the end of the booster rod before installation; it should slide smoothly onto it and attach to the studs via the flange before anything else. Fit the master cylinder 1 into the mounting studs that come with the booster and screw on the nuts 2 to a tightness of 10 Nm (or 90 in. lbs.). After that, put the IPM 4 and its fasteners back in and fit the left front wheel well. After that, attach the vacuum hose to check valve 2 and resume connecting the electrical connectors 4, 5 and 7. Then, attach the wiper arm and cowl assembly 1 to the vehicle.