OEM 2006 Dodge Caravan Brake Booster

2006 Dodge Caravan Brake Booster Parts and Q&A

• Q: How to Service a Brake Booster on 2006 Dodge Caravan?

  A: With an engine off, pump the right-hand brake pedal several times until a solid feel is reached to ensure the vacuum in the power brake booster is relieved. Unhook the negative and positive battery cable, remove the battery thermal guard shield and get rid of the battery, its clamp and nut. If you have a vacuum with a speed control button, disconnect the vacuum hose at the vacuum tank and then take out the two nuts and bolt that attach the battery tray. Remove the wiring harness from the speed control servo, take out the two nuts holding it and set the servo aside. On vehicles with a 2.5L diesel engine, take out the coolant recovery pressure container and bracket. Separate the wires from the brake fluid level switch and wipe down the point at which the master cylinder meets the booster using Mopar Brake Parts Cleaner. Slide a flathead screwdriver under the two nuts holding the master cylinder to the booster, taking the master cylinder out and always remember to put the vacuum seal back in place whenever you disconnect the master cylinder. Simply take the vacuum hose from the check valve on the booster, without removing the check valve. On the underside of the instrument panel, take out the cover for the booster input rod trim and unclip the retaining pin from the brake pedal torque shaft with a small screwdriver. You should then toss out the worn retaining clip and install a new one when everything is back together. Detach the three anchoring nuts at the dash panel and pull forward on the fourth to slide the booster forward. Place the booster on the dash panel so that the upper and lower attaching screws are visible and then tighten them to 29 Nm (250 inch lbs.). Have the brake pedal torque shaft pin lubricated and use a fresh retaining clip to hold the booster input rod in place. Link the hose from the check valve to the vacuum pump once again and put the vacuum seal back on the master cylinder before attaching it to the booster with the push rod thrusting the piston down. Put two nuts on the master cylinder and tighten them to 25 Nm (225 inch lbs.), then connect the wiring harness to the brake fluid level switch. Wherever it is part of the process, reinstall the coolant recovery pressure container and speed control servo, fastening their mounting nuts to 14 Nm (124 inch lbs.). Attach the battery tray to its place, using two nuts and one bolt and then reconnect the battery. Also, replace the brake lamp switch if needed. After that, bleed the brakes on the front wheels and drive on the road to test whether the brakes are working.