OEM 2006 Dodge Durango Brake Booster

2006 Dodge Durango Brake Booster Parts and Q&A

• Q: How to Service and Repair a Brake Booster with ESP on 2006 Dodge Durango?

  A: The first step is to depress the brake pedal five times to get rid of all the remaining vacuum in the booster unit while working on ESP. Take out the fluid from the reservoir first and after that, detach the wiper arm and cowl assembly. Separate the electrical connectors from the master cylinder and after that remove its bolts. Pull away from the check valve the hoses that lead to it, leaving the check valve in place and proceed to take out the inner wheel well. Take out the fasteners holding the IPM and slide the IPM toward the front so you can remove the master cylinder. Carefully pull out the master cylinder and reservoir assembly from the booster, holding it so it stays perpendicular to the front of the booster to stop the output rod from shifting. Remove the master cylinder from the booster, moving it to the engine side and unclip the brake lamp switch from the booster push rod on the brake pedal. Unbolt the mounting nuts that hold the brake booster to the front cowl panel and take everything out, including the spacer block and gasket, along with the booster. After removing, clean the brake booster cowl mounting hole. For assembly, put the spacer block and gaskets in first if they were loosened, then insert the booster studs into the cowl panel holes and rest the booster in place. Secure the new booster nuts to 28 Nm (250 inch lbs.), attach the booster push rod to the brake pedal and fix it with the clip. Reach the latch out, adjust its position and install it into the master cylinder plunger sleeve through its central hole with the spring that goes over the ligament on the brake booster output rod. Make sure there is a vacuum seal at both the shoulder of the master cylinder flange and its neck before putting the master cylinder onto the bolts and tightening the nuts to 10 Nm (90 inch lbs.). Move the master cylinder plunger up over the booster output rod and then mount the cylinder. Insert the IPM with its fasteners, the left front wheel well, the vacuum hose to the check valve, reconnect the electrical connectors and then mount the wiper arm and cowl assembly.