OEM 2005 Dodge Caravan Brake Booster

2005 Dodge Caravan Brake Booster Parts and Q&A

• Q: How to Service and Repair a Brake Booster on 2005 Dodge Caravan?

  A: First, empty the vacuum inside the power brake booster by pressing the brake pedal several times while the engine is off until it cannot be pressed down any further. Turn off the negative and positive battery cables, remove the battery thermal guard shield and take away the battery plus its clamp and nut. Take out the engine coolant tube from the battery tray and, if your vehicle has speed control, take out the vacuum hose at the vacuum tank too. Unfasten two nuts and one bolt on the battery tray, next release the wiring harness from the speed control servo and remove its mounting nuts so you can take out the servo. Take the wiper module out and pull the wiring harness from the brake fluid level switch in the master cylinder reservoir. Wash that spot where the master cylinder joins the power brake booster using a solvent such as Mopar Brake Parts Cleaner. Remove the main and secondary brake tubes from either the ABS unit or junction block, then place sealing caps in each open outlet. Gently take out the nuts connected to the master cylinder and the booster and pull the master cylinder out straight. At the same time, remember to replace the vacuum seal every time you remove the master cylinder. Take the vacuum hose off the check valve on the booster, but leave the check valve attached to the engine. After opening the vehicle, remove the silencer plate and find where the booster input rod is attached to the brake pedal. Open the retaining clip on the brake pedal pin with a small screwdriver, then move the booster input rod off the pin. Take out the four nuts joining the power brake booster to the dashboard and push it forward until you can remove it from under the hood. When installing, align the power brake booster on the panel above the pedal, possibly by pushing the booster input rod and add and tighten the mounting nuts to 29 Nm (250 inch lbs.). Apply lubriplate to the brake pedal pin, push the booster input rod on to the pin and attach a new retaining clip and replace the brake lamp switch with a new one. Connect the silencer panel in place, put the vacuum hose coming from the vacuum pump on the check valve and your master cylinder should be fitted with a fresh vacuum seal. Attach the master cylinder to the booster, so that the push rod lines up with the piston and tie it down with two nuts tightened to 25 Nm (225 inch lbs.). Connect the wiring harness back to the brake fluid level switch and link both brake tubes together, tightening the referenced nuts with between 145 in lbs. and 17 Nm of torque. Put back the wiper module, speed control servo if you have one and the battery tray, making sure it is secure with two nuts and one bolt tightened to 14 Nm (124 inch lbs.). If your car uses speed control, reattach the servo vacuum hose, then insert the air inlet resonator and hoses, secure the engine coolant filler neck and attach your battery and all its wires. Make sure to remove the bleed tube from the base brakes at times and road test enough to guarantee they are working appropriately.