Pacifica V6-3.8L VIN L (2005)
Vacuum Brake Booster: Service and Repair
POWER BRAKE BOOSTER
REMOVAL
1) Move driver's seat to full rearward position.
2) Disconnect negative (-) battery cable from battery post and isolate.
3) Remove battery from vehicle.
CAUTION: Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This
is necessary to prevent power brake booster from sucking in any contamination as master cylinder is removed. This can be done simply by
pumping brake pedal, with vehicle's engine not running, until a firm feeling brake pedal is achieved.
4) With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes).
5) Remove nuts fastening coolant recovery bottle in place and reposition bottle with hoses attached out of way.
CAUTION: Before removing master cylinder from power brake vacuum booster, master cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles from failing into power brake vacuum booster.
6) Thoroughly clean all surfaces of brake fluid reservoir and master cylinder, paying special attention to area where master cylinder attaches to power
brake booster. Use only Mopar Brake Parts Cleaner or equivalent.
7) Disconnect wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig. 48).
8) Disconnect primary and secondary brake tubes coming from master cylinder at ABS ICU (Fig. 54). Cap off brake tubes and install sealing plugs in
open brake tube outlet ports of ICU.
9) Remove two nuts attaching master cylinder to power brake booster (Fig. 49).
10) Slide master cylinder straight out of power brake booster.
CAUTION: Seal on rear of master cylinder is used to create seal for holding vacuum in power brake vacuum booster. Vacuum seal on master
cylinder MUST be replaced whenever master cylinder is removed from power brake vacuum booster.
11) Remove vacuum seal located on mounting flange of master cylinder. Vacuum seal is removed from master cylinder by carefully pulling it off rear
of master cylinder. Do not attempt to pry seal off master cylinder by inserting a sharp tool between seal and master cylinder casting.