Brake System Issue

Tiny
GREGORY MICHAEL YATES
  • MEMBER
  • 1998 CHRYSLER CONCORDE
  • 3.2L
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 151,000 MILES
Hi,

I want to see if anyone can help me. I needed to press down hard on brake pedal to get car to slow down and stop. So, I replaced master cylinder,
I replaced Power Brake Booster I bench bled master cylinder before installing. Brakes then worked good until today.

Now, once again, I need to press down hard to slow down/stop car. Brake fluid level is fine.

Did the Re-manufactured Brake Booster I just installed, fail?
Bad ABS Module?
Air in brake line? I read I can't bleed ABS brakes. You need a scanner.

Only Check Engine Light code is P0160
For O2 Sensor.
I did see Traction Light turn on briefly then it went off.
I tested brake booster by pumping brake pedal 6-8 times with engine off then keep pressure on pedal while I started engine and pedal dropped.
What say you?
Is it time to take to Mechanic?
Do you
have the same problem?
Yes
No
Saturday, May 2nd, 2020 AT 10:41 PM

14 Replies

Tiny
ASEMASTER6371
  • EXPERT
Good morning,

Do you feel like you lost the power assist?

Is the pedal the correct height when you apply the brakes?

https://www.2carpros.com/articles/how-to-bleed-or-flush-a-car-brake-system

From your description, it does sound like the new booster has failed.

You can change just the booster with taking off the master cylinder.

Roy

REMOVE

Correctly Isolated Remote Ground Cable
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1. Remove the battery ground cable from the ground stud on the right strut tower. Then, correctly isolate the ground cable by installing the cable isolator on the ground stud.

Wiper Arm Attachment To Pivot
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2. Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nut. Remove the nut attaching each wiper arm to its pivot.
3. Remove the wiper arms from the pivots. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots.

Wiper Module And Cowl Cover
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4. Remove the wiper module cover and cowl cover from the vehicle.

Reinforcement Attachment To Vehicle
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5. Remove the 8 bolts, attaching the reinforcement to the strut towers and the 1 bolt attaching the wiper module to the reinforcement. Remove the reinforcement from the vehicle.
6. Disconnect the wire connector from the brake fluid level sensor on the right side of the master cylinder reservoir.

Master Cylinder Mounting
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7. Remove the 2 nuts attaching the master cylinder to the vacuum booster.

Master Cylinder Positioning
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8. Carefully slide master cylinder off vacuum booster with brake lines attached, and position it backwards, on top of left engine cylinder head cover.
9. Disconnect vacuum hose from power brake booster check valve. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER.
10. From under instrument panel, position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip.
11. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull retainer clip off pin. Discard retainer clip it is not to be reused, replace only with a new retainer clip.
12. Remove the four nuts that attach the vacuum booster to the vehicle dash panel. Nuts are accessible from under the dash panel in the area of the steering column and pedal bracket.

Wiper Crank Lever Positioning
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13. Rotate the windshield wiper motor crank lever until the crank lever points in the 12 o'clock position.
14. Slide the vacuum booster out of the dash panel, and remove from vehicle.

CAUTION: Do not attempt to disassemble the vacuum booster. It is serviced ONLY as a complete assembly.

INSTALL
1. Position vacuum booster on dash panel.
2. Install and tighten the 4 power brake booster to dash panel mounting nuts to 29 Nm (250 inch lbs.) torque.
3. Using lubriplate, or equivalent, coat the bearing surface of brake pedal pin.
4. Connect vacuum booster input rod to brake pedal pin and install a NEW retainer clip. Use only a new retainer clip DO NOT USE the old clip.

NOTE: Before installing master cylinder, reposition under hood wiring harness above master cylinder mounting studs, in front of booster.

5. Carefully position master cylinder on vacuum booster. Position wire harness routing bracket onto right master cylinder mounting stud.
6. Install and tighten the 2 master cylinder to vacuum booster mounting nuts to 29 Nm (250 inch lbs.) torque.
7. Reconnect brake fluid level sensor connector.
8. Connect all vacuum hoses onto the vacuum booster check valve.
9. Check stop light switch operation.
10. Install the wiper module reinforcement on the vehicle. Install the 8 bolts, attaching the reinforcement to the strut towers. Install the bolt attaching the wiper module to the reinforcement.
11. Install the covers over the wiper module and the cowl. Install and securely tighten the attaching screws.
12. Reconnect the battery ground cable to the ground stud on the shock tower.
13. Turn windshield wipers on, then off, in order to park wipers in the proper position before installing wiper arms.
14. Install the wiper arms on the pivots. Install and securely tighten the wiper arm to pivot attaching nuts. Install the caps on the wiper arms covering the pivot nuts.
15. Verify proper operation of the brake booster and brake system.
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Sunday, May 3rd, 2020 AT 4:44 AM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Hi ASEMASTER6371,

I guess I did lose Power Assist. And the petal height looked okay. I will remove booster like you said. Wow, you listed all the steps and included images! Very detailed. I appreciate it!
I will respond and let you know how it goes. Stay Safe!

Thanks again!
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Sunday, May 3rd, 2020 AT 8:02 AM
Tiny
ASEMASTER6371
  • EXPERT
You are welcome.

Always glad to help.

Roy
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Sunday, May 3rd, 2020 AT 9:03 AM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Hi, before I replace booster.
I want to ask you what you think about the possibility that ABS module is the problem.
Since I just recently installed booster and as I said, this booster passed the operating check and air-tightness check.
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Monday, May 4th, 2020 AT 4:13 PM
Tiny
ASEMASTER6371
  • EXPERT
I doubt the ABS module would cause a hard pedal to push. It does not control the easy feel of the pedal.

Make sure you have good vacuum at the booster with the engine running at idle.

Roy
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Monday, May 4th, 2020 AT 4:29 PM
Tiny
ASEMASTER6371
  • EXPERT
Did you respond? I got an email but nothing cmae through?

Roy
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Tuesday, May 5th, 2020 AT 3:23 AM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Hi,

I did not respond to last message. But I am now. I swapped out p booster. And now I have power assist again. I don't need to press down with all my might to get car to stop. Since I replaced master cylinder-I bench bled first. Should I take car to mechanic to have brakes bled and have brake system checked out? Maybe brake system flush? As this car is 22 years old.
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Thursday, May 7th, 2020 AT 2:00 PM
Tiny
ASEMASTER6371
  • EXPERT
That would be a good idea. Have them check the work.

Yes, have the system flushed and bled.

https://www.2carpros.com/articles/how-to-bleed-or-flush-a-car-brake-system

Roy
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Thursday, May 7th, 2020 AT 2:38 PM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Okay.
I am now concerned that when I was pushing brake pedal down very hard to stop car.
I pushed crud into new master cylinder.
Like I as I read about in guide from link you provided.
I think I want to go to dealer so it is done correctly with scanner.
Do you think dealer is best as opposed to Goodyear, or some other shop?

Thanks!
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Thursday, May 7th, 2020 AT 7:07 PM
Tiny
ASEMASTER6371
  • EXPERT
Any shop can perform this routine. You will pay at least double at a dealer but that is up to you.

I would not hesitate to take it to a private shop to have this performed.

Roy
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Friday, May 8th, 2020 AT 3:25 AM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Got it. Thanks!
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Saturday, May 9th, 2020 AT 10:30 AM
Tiny
ASEMASTER6371
  • EXPERT
You are welcome.

Always glad to help.

Roy
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Sunday, May 10th, 2020 AT 2:27 AM
Tiny
GREGORY MICHAEL YATES
  • MEMBER
Follow up. I returned Cardone Reman to Advance Auto and they gave me a new one. I installed and had mechanic flush and bleed brakes. Brakes are okay.
Thanks again!
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Thursday, June 25th, 2020 AT 2:32 PM
Tiny
ASEMASTER6371
  • EXPERT
Good deal.

You are welcome.

Always glad to help.

Roy
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Thursday, June 25th, 2020 AT 2:36 PM

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