RAM 3500 HD Truck 4WD L6-6.7L DSL Turbo VIN A (2007)
Hydraulic Brake Booster: Removal and Replacement
Removal
REMOVAL
NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the
booster.
1. With engine off depress the brake pedal 5 times to discharge the accumulator.
2. Remove brake lines from master cylinder.
3. Remove mounting nuts from the master cylinder.
4. Remove the bracket from the hydraulic booster lines and master cylinder mounting studs.
5. Remove the master cylinder (3).
6. Remove the return hose (4) and the two pressure lines (1&5) from the hydraulic booster (2).
7. Remove the booster push rod clip, washer and rod remove from the brake pedal.
8. Remove the mounting nuts from the hydraulic booster and remove the booster.
Installation
INSTALLATION
1. Install the hydraulic booster (2) and tighten the mounting nuts to 28 Nm (21 ft. lbs.).
2. Install the booster push rod, washer and clip onto the brake pedal.
3. Install the master cylinder (3) on the mounting studs. and tighten the mounting nuts to 23 Nm (17 ft. lbs.).
4. Install the brake lines to the master cylinder and tighten to 19 Nm (170 in. lbs.).
5. Install the hydraulic booster line bracket onto the master cylinder mounting studs.
6. Install the master cylinder mounting nuts and tighten to 23 Nm (17 ft. lbs.).
7. Install the hydraulic booster pressure lines (1&5) to the bracket and booster.
8. Tighten the pressure lines to 41 Nm (30 ft. lbs.).
NOTE: Inspect o-rings on the pressure line fittings to insure they are in good condition before installation. Replace o-rings if necessary.
9. Install the return hose (4) to the booster.