Mopar 68144663AA Booster-POWERBRAKE

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If the brake booster is being replaced due to power steering fluid contamination, flush the power steering fluid contamination, flush the power steering system prior to installing the new brake booster. Disconnect the cable(s) from the negative battery terminal(s). With the engine off, depress the brake pedal several times to discharge the accumulator. Remove the master cylinder. Remove the return hose and pressure line(s) from the brake booster. Working inside the vehicle, remove the clip and washer, then disengage the brake booster pushrod from the brake pedal. Remove the brake booster mounting nuts. Working inside the engine compartment, remove the brake booster from the firewall. Installation is the reverse of removal. Tighten the booster mounting nuts and the pressure lines. Bleed the brake hydraulic system, then bleed the power steering system.

The power brake booster unit requires no special maintenance apart from periodic inspection of the vacuum hose and the case. Disassembly of the power unit requires special tools and is not ordinarily performed by the home mechanic. If a problem develops, it's recommended that a new or factory rebuilt unit be installed. To perform an operating check, depress the brake pedal several times with the engine off and make sure that there is no change in the pedal reserve distance. Then, depress the pedal and start the engine. If the pedal goes down slightly, operation is normal. For an airtightness check, start the engine and turn it off after one or two minutes. Depress the brake pedal several times slowly. If the pedal goes down farther the first time but gradually rises after the second or third depression, the booster is airtight. Another airtightness check involves depressing the brake pedal while the engine is running, then stopping the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight. To remove the power brake booster, first remove the master cylinder. Then, disconnect the vacuum hose from the power brake booster and disconnect the power brake pushrod from the top of the brake pedal by prying off the clip. Remove the nuts attaching the booster to the firewall and carefully lift the booster unit away from the firewall and out of the engine compartment. To install the booster, place it into position and tighten the retaining nuts. Connect the booster pushrod to the brake pedal and install the master cylinder. Connect the brake lines to the master cylinder and tighten all fitting nuts securely. Connect the vacuum hose to the brake booster assembly. Finally, bleed the brake system and carefully test the operation of the brakes before placing the vehicle in normal operation.