OEM 2005 Dodge Grand Caravan Brake Booster

2005 Dodge Grand Caravan Brake Booster Parts and Q&A

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

  A: In order to service the power brake booster in a right- hand drive car, one has to ensure that the power brake booster is void of vacuum by pumping the brake pedal with the engine off till one gets a firm pedal. Unfasten the negative and positive battery terminals, detach the battery thermal guard shield and pull out the battery, as well as its clamp and nut. Being fitted with speed control, disconnect the vacuum hose at the vacuum tank and remove the battery tray, taking out the two nuts and one bolt holding it. Disconnect the wiring harness off the speed control servo and place the two nuts in the holders and put the servo to a side. In cars with 2.5L diesel engine, take out the coolant recovery pressure container, as well as the bracket. Unplug the wiring harness at the brake fluid level switch, in the master cylinder fluid reservoir, and the area around where the master cylinder is attached to the power brake booster cleaned with a solvent such as Mopar Brake parts cleaner. Loosen the two nuts which hold the master cylinder in position, on to the booster and pull the master cylinder out leaving it aside. Without removing the check valve itself disconnect the vacuum hose at the check valve on the booster. Remove the booster input rod trim cover under the instrument panel and with a small screwdriver take away the retaining clip on the brake pedal torque shaft pin, discarding the clip-replacement clip will be used at reassembly. Disconnect the booster input rod at the pedal torque shaft pin, then disconnect the three easy access mounting nuts and loosen the fourth nut and work the booster input forward until it may be totally removed through the engine compartment. When fitting the new power brake booster, place it on the dash panel and the upper and lower mounting bolts and screw them by tightening to 29 Nm (250 inch lbs.). Apply lubriplate or similar to the brake pedal taq shaft pin, replace the booster input rod and retaining clip and (re)place the trim cover. Install the vacuum line so that it ties into the check valve on the booster and make sure that you replace with a new one at that rear seal on the master cylinder. Take a sucker out to dislodge the outdated vacuum piping and put in another vacuum piping on the master cylinder. Fix the master cylinder on the booster at a right angle to the piston and push rod and hold the two nuts down with 25 Nm (225 inch lbs.). Put the wiring harness back on the brake fluid level switch and should one be used, put the coolant recovery pressure container back together and place the speed control servo back on with the wiring connector and tighten the nuts to 14 Nm (124 inch lbs.). Re-install the battery tray by getting it fixed with a couple of nuts and a bolt and put the servo vacuum hose on it in case it has one. Install the battery, clamp and both battery cables in the proper positions and fit the thermal guard shield again. Make a replacement of the brake lamp switch with a new one, bleed the base brakes where necessary and do a road test to confirm the proper operation of the brakes.