Pacifica V6-3.8L VIN L (2005)
12) Loosen 2 bolts fastening ABS ICU bracket to frame rail (Fig. 55).
13) Lift ICU off frame rail bolts and lower ICU onto top of transaxle.
14) Disconnect vacuum hose from check valve on face of booster. Do not remove check valve from booster.
15) Access and remove knee blocker airbag.
16) Remove booster push rod from pin on brake pedal (Fig. 53). To do so:
a) Position small screwdriver between center tang on power brake booster brake pedal pin retaining clip.
b) Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin, then slide retaining clip off brake pedal pin.
c) Discard retaining clip. It is not to be reused. Install NEW retaining clip when assembling.
17) Slide booster push rod off brake pedal pin.
18) Remove and discard brake lamp switch (Fig. 53). Do not reuse switch; install NEW switch on Installation.
19) Remove four power brake booster mounting nuts (Fig. 53).
20) Slide power brake booster forward and remove through engine compartment.
INSTALLATION
NOTE: Before installing booster, make sure there is a NEW booster seal placed over push rod and mounting studs on rear of booster.
1) Install power brake booster through engine compartment, guiding push rod and mounting studs through dash panel.
2) Install four power brake booster mounting nuts (Fig. 53). Tighten nuts to 28 Nm (21 ft. lbs.) torque.
3) Slide booster push rod onto brake pedal pin (Fig. 53). Install NEW retaining clip securing push rod to brake pedal.
4) Install and adjust NEW brake lamp switch (Fig. 53).
5) Install knee blocker airbag as well as all components necessary to access it.
6) Lift ABS ICU up and place mounting bracket over two mounting bolts in frame rail (Fig. 55). Tighten bolts to 24 Nm (18 ft. lbs.) torque.
CAUTION: When replacing master cylinder on vehicle, a NEW vacuum seal MUST be installed on master cylinder.
7) Install NEW vacuum seal on rear of master cylinder making sure seal fits squarely in mounting groove.
8) Position master cylinder on studs of power brake booster (Fig. 49), aligning booster push rod with master cylinder piston.
9) Install two master cylinder mounting nuts (Fig. 49). Tighten both mounting nuts to 25 Nm (225 inch lbs.) torque.
10) Thread primary and secondary brake tubes into ICU ports as shown (Fig. 49). Brake tubes must be held securely when tightened to control
orientation of flex section. Tighten tube nuts to 14 Nm (120 inch lbs.) torque.
11) Connect wiring harness connector to brake fluid level switch mounted in brake fluid reservoir (Fig. 48).
12) Place coolant recovery bottle in its normal mounted position and install nuts fastening it in place.
13) Install battery and connect battery cables to battery.
14) Fill master cylinder with clean, fresh Mopar Brake Fluid or equivalent, then bleed brakes.
15) Road test vehicle to ensure proper operation of brakes.