B. Replace Power Brake Booster Assembly
1. With the ignition key in the OFF position, disconnect the battery.Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. For Cherokee (XJ) vehicles, remove the air filter housing cover.
3. For Wrangler (TJ) vehicles, remove the evaporative canister and bracket assembly and set it aside.
4. For Grand Cherokee (ZJ) vehicles, disconnect the crankcase ventilation system hose from the air filter housing cover and set the hose aside.
5. Remove the two (2) nuts that secure the combination valve bracket to the power brake booster (Figure 2). Carefully pull the combination valve bracket forward.
6. Remove the two (2) nuts that secure the master cylinder to the power brake booster (Figure 2).
7. Carefully pull the master cylinder, combination valve and the attached brake lines forward.
8. Disconnect the vacuum hose from the power brake booster check valve.
9. For Cherokee (XJ) vehicles equipped with ABS, loosen the three (3) ABS HCU bracket fasteners.
10. For Cherokee (XJ) vehicles, remove the lower steering column cover and knee bolster.
11. Inside of the vehicle, remove the retainer clip that holds the brake booster push rod onto the brake pedal pin (Figure 3). Discard the clip.
12. Remove the four (4) nuts that secure the brake booster to the dash panel (Figure 4).
13. In the engine compartment, slide the booster forward, tilt it upwards slightly and then remove it from the engine compartment.
14. Remove the dash panel seal from the brake booster.
15. Install the dash panel seal on the new brake booster.
16. Install the new brake booster into position on the dash panel.
17. Inside of the vehicle, lubricate the brake pedal pin and bushing with Mopar multi-mileage grease or equivalent.
18. Loosely install the four (4) brake booster attaching nuts (Figure 4).
19. Slide the booster push rod over the pedal pin. Secure the push rod with the provided retainer clip (Figure 3).
20. Tighten the four (4) brake booster attaching nuts to 29 ft-lbs (39 N.m).
21. Adjust the brake switch by pulling up on the brake pedal as far as it will go. A racheting noise from the brake switch is considered normal.
22. For Cherokee (XJ) vehicles, install the knee blocker and lower steering column cover.
23. In the engine compartment, connect the vacuum hose to the brake booster.
24. Install the master cylinder onto the new brake booster (Figure 2). Tighten the attaching nuts to 155 in-lbs (18 N.m).
25. Install the combination valve onto the new brake booster (Figure 2). Tighten the attaching nuts to 155 in-lbs (18 N.m).
26. For Cherokee (XJ) vehicles equipped with ABS, tighten the three (3) ABS HCU bracket fasteners securely.
27. For Cherokee (XJ) vehicles, install the air filter housing cover.
28. For Wrangler (TJ) vehicles, install the evaporative canister and bracket assembly.
29. For Grand Cherokee (ZJ) vehicles, connect the crankcase ventilation system hose to the air filter housing cover.
30. Connect the negative battery cable.