OEM 2003 Dodge Ram 2500 Brake Booster

2003 Dodge Ram 2500 Brake Booster Parts and Q&A

• Q: How to Service and Repair a Hydraulic Brake Booster on 2003 Dodge Ram 2500?

  A: In case the hydraulic booster is being replaced because of contaminated power steering fluid, flush the power steering system after draining the fluid before replacing the boost. Turn off the engine and continue by pressing down the brake five times to drain the accumulator. Then, take out the brake lines from the master cylinder and remove the mounting nuts. While the bracket is still attached to the car, take it off the hydraulic booster lines and the mounting studs for the master cylinder, then remove the latter. Unplug the return hose and the two pressure lines from the booster and unclip the push rod, washer and rod from the pedal. Take off the nuts on the hydraulic booster and lift out the booster from the vehicle. Attach the hydraulic booster and tighten the nuts to 28 Nm (21 ft. lbs.). Mount the booster push rod, washer and clip on the brake pedal after that and attach the master cylinder to the studs using the nuts, tightening each to a force of 23 Nm (17 ft. lbs.). Attach the brake lines to the master cylinder, pulling them firmly until they reach a torque of 19 - 200 Nm (170 - 200 in. lbs.) and then fit the hydraulic booster line bracket onto the master cylinder studs. Attach the master cylinder to the mounting position, ensuring the nuts are tightened to 23 Nm (17 ft. lbs.) and fit the booster pressure lines to both the bracket and the booster. Secure the lines by tightening to 41 Nm (30 ft. lbs.). Mobile art installations require you to inspect the pressure line O-rings for cracks before installing and you should replace them if necessary. Attach the hose from the booster to the return on the unit, bleed the base brake system and add fresh Mopar Atf+4 fluid to the steering pump, using only this type as other fluids can harm your pump and system. Next, bleed the system of the hydraulic booster.