Chrysler Concorde 2004 Service Manual page 1508

5 - 42 BRAKES - BASE BRAKE SYSTEM
PEDAL (Continued)
(5) Install the nut on the end of the brake pedal
pivot shaft. Tighten the nut to a torque of 34 N·m (25
ft. lbs.).
(6) Install the power brake booster input rod on
the brake pedal pin.
CAUTION: When installing the retaining clip on the
brake pedal pin, a NEW retaining clip must be used
to ensure the retention of the power brake booster
input rod.
(7) Install a new retaining clip (Fig. 71) on the
brake pedal pin.
(8) Using Mopar Lubriplate or an equivalent,
lightly lubricate the surface of the brake pedal
striker where the plunger of the brake lamp switch
contacts it.
NOTE: Prior to installing the brake lamp switch into
its bracket, the plunger must be moved to its fully
extended position using the procedure in Step 9.
(9) Hold brake lamp switch firmly in one hand.
Using other hand, pull outward on the plunger of the
brake lamp switch until it has ratcheted out to its
fully extended position.
(10) Install the brake lamp switch in the brake
pedal bracket (Fig. 70). Install it using the following
procedure. Depress the brake pedal as far down as
possible. Then while holding brake pedal down, align
the index key on switch with notch in square hole of
mounting bracket. When the switch is fully installed
into the bracket, rotate the switch in a clockwise
direction approximately 30 degrees until it locks into
place.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the brake lamp
switch. If to much force is used, damage to the
brake lamp switch or striker can result.
(11) Gently release/pull back the brake pedal until
it stops moving. This will cause the switch plunger to
ratchet back to its correctly adjusted position.
(12) Connect the remote ground cable to the
ground stud on the right front strut tower.
(13) Check the operation of the brakes and brake
lamp switch.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster assembly mounts on the
engine side of the dash panel. It is externally con-
nected to the brake pedal by an input push rod
extending out the rear of the booster (Fig. 72). The
master cylinder is bolted to the front of the power
brake booster assembly.
Fig. 72 Power Brake Booster
1 - VACUUM CHECK VALVE
2 - OUTPUT ROD
3 - POWER BRAKE BOOSTER ASSEMBLY
4 - INPUT ROD
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
A vacuum check valve is mounted on the power
brake booster body. A vacuum line connects the
booster (check valve) to the intake manifold. Depend-
ing on the engine combination, different vacuum hose
routings are required.
LH