Dodge Journey: Removal

LEFT-HAND-DRIVE

CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.

1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.

2. Disconnect the negative (ground) cable from the battery and isolate the cable.

Brakes
Fig. 18: COWL TOP SCREEN

3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3).

4. Remove the wiper arms.

Brakes
Fig. 19: COWL SCREEN

5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90º clockwise to release the screen. Remove the cowl screen (3).

Brakes
Fig. 20: WHEELHOUSE BRACE

6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers.

7. Remove the wheelhouse brace (2).

8. Remove the master cylinder.

Brakes
Fig. 21: REAR BRAKE TUBES AT JUNCTION BLOCK

9. Disconnect the rear brake tubes (1) at the junction block (2). Install plugs at all of the open brake tubes.

Brakes
Fig. 22: VACUUM HOSE AT BOOSTER - LHD

10. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster.

11. If equipped, remove the silencer pad below the steering column opening cover.

Brakes
Fig. 23: STOP LAMP SWITCH REMOVAL

12. Remove the stop lamp switch (2). Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008.

Brakes
Fig. 24: BRAKE PEDAL CLIP

13. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip.

14. Slide the booster push rod (1) off the brake pedal pin (3).

Brakes
Fig. 25: PEDAL AND BOOSTER MOUNTING - LHD

15. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel.

16. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment.

RIGHT-HAND-DRIVE

CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.

1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.

2. Disconnect the negative (ground) cable from the battery and isolate the cable.

3. Remove the engine appearance cover.

Brakes
Fig. 26: COWL TOP SCREEN

4. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3).

5. Remove the wiper arms.

Brakes
Fig. 27: COWL SCREEN

6. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90º clockwise to release the screen. Remove the cowl screen (3).

Brakes
Fig. 28: WHEELHOUSE BRACE

7. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers.

8. Remove the wheelhouse brace (2).

Brakes
Fig. 29: MODULE -WIPER

9. Disconnect the electrical connector (2) from the wiper motor.

10. Remove three bolts (1) from the wiper module.

11. Remove the wiper module from the vehicle.

Brakes
Fig. 30: VACUUM HOSE AT BOOSTER - RHD

12. Remove the booster vacuum hose routing clip (4) from the master cylinder mounting stud.

13. Remove the vacuum hose routing clip (3) from the stud on the dash panel.

14. Remove the master cylinder.

Brakes
Fig. 31: VACUUM HOSE AT BOOSTER - RHD

15. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from the power brake booster.

16. Remove both brake tube routing clips with tubes from the studs on the dash panel. Do not bend the brake tubes.

Brakes
Fig. 32: STOP LAMP SWITCH REMOVAL

17. Remove the stop lamp switch (2).Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008.

Brakes
Fig. 33: BRAKE PEDAL CLIP - RHD

18. Remove the retaining clip (1) securing the power brake booster push rod (2) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip.

19. Slide the booster push rod (2) off the brake pedal pin (3).

20. If equipped with a manual transaxle, remove the clutch master cylinder from the pedal bracket assembly and dash panel.

Brakes
Fig. 34: PEDAL AND BOOSTER MOUNTING - RHD

21. Remove the four nuts (4) attaching the power brake booster (1) to the dash panel.

22. Slide the power brake booster (1) forward clearing the dash panel, then remove it from the vehicle.

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