OEM Dodge Grand Caravan Brake Booster

Dodge Grand Caravan Brake Booster Parts and Q&A

• Brake Booster
  4721802AC
  Q: How to Service and Repair a Right-Hand-Drive Brake Booster on Dodge Grand Caravan?

  A:

  The first thing to do when servicing the power brake booster on a right-hand-drive vehicle is to push the driver's seat right back. Remember to pump all the air out of the power brake booster using the brake pedal first, before unseating the master cylinder to prevent dirt or oils from polluting the system. After that, unwind the master cylinder (7) and if desired, pull back the shield (3) from the booster (2). Take off the vacuum hose (1) at the check valve on the booster face (2) without taking out the check valve. If the vehicle's pedal adjustment includes a stop lamp switch, open the wiring connector (1) at the switch (2), turn the switch clockwise to align the tabs with the bracket slot (3) and take out and discard the switch since you'll need to install a different one when you reassemble everything. If your pedal does not adjust, take off the connector from the stop lamp switch, turn it clockwise until the tabs align with the slot in the bracket (1), remove the switch and throw it out; while reassembling, put in a new switch. To remove the brake booster push rod (2), slide a screwdriver between the center of the clip on the brake pedal pin (3), turn it to move the clip over onto the pin, then try to slide it off the pin and discard it. After that, take out the power brake booster mounting nuts (3), push it forward and remove it from above the engine compartment.
• Brake Booster
  4797614
  Q: How to Maintain a Brake Booster on Dodge Grand Caravan?

  A:

  First, pull the brake pedal 4 to 5 times with the engine off, to remove the reserve vacuum from the system. Yank out the battery, clear it, take the thermal shield off, then remove the resonator and hoses from the Throttle Body and the air cleaner housing. If you have speed control, remove the servo wiring and pull out the vacuum tubes from the servo and vacuum reservoir. Pry loose the bolt that holds the control servo bracket to the Battery Tray and move the bracket forward. Remove the two bolts and nut holding the battery tray to the body of the vehicle and separate the wiring harness from all the connections to the EGR Valve transducer, Throttle Position Sensor and AIS motor. Unscrew the two bolts connecting the throttle body to the intake manifold and remove the clip from the wiring on the bracket for the throttle cable. Next, take the throttle body and the bracket out together. Separate the wire from the brake level sensor in the reservoir, apply a solvent to clean around the point where the master cylinder links to the booster near the wiper module and take out the clip and drain hose that are located there. Unscrew the nuts that hold the master cylinder onto the vacuum booster and take notice that the brake tubes do not need to be taken apart. As one unit, remove the master cylinder and brake tubes and set it on the left motor mount. Take out the EGR valve and vacuum transducer as a group from the intake manifold and cut the vacuum hose from the check valve on the booster without touching the check valve. You'll find the input rod attached to the vacuum booster under the instrument panel; remove it from the pin using a screwdriver and dispose of the clip. Pop out the four nuts at the corner of the power brake vacuum booster which connect it to the dash panel from under the dash and pull the booster forward and down to slide it off. When installing the new vacuum booster, prevent heater hoses from becoming trapped, place it on the dash panel and tighten the four nuts to 29 Nm (250 inch lbs.). Apply lubriplate to the brake pedal pin, put the new retaining clip in place, attach the vacuum hose to the check valve, fit the EGR valve and transducer with the bolts tightened to 22 Nm (200 inch lbs.) and reinstall the vacuum hose to the body end. No sharp tools are to be used-instead, seal the master cylinder, place it on the studs on the vacuum booster and tighten the two nuts to a value of 25 Nm (225 inch lbs.). Next, attach the wiper module drain tube and tie strap, wire up the Brake Fluid Level Sensor to the harness and put back the throttle body and throttle cable bracket with both bolts attached at 25 Nm (225 inch lbs.). After reconnecting the throttle position sensor, AIS motor and EGR valve transducer wiring harnesses, reinforce the battery tray with the two bolts and nut secured to 14 Nm (125 inch lbs.). When that's needed, reattach the speed control servo and bracket, fit the wiring harness and vacuumlines and refit the air inlet resonator and its hoses. Be sure to replace all the electronic parts, including the battery, battery thermal guard and battery cables and then operate the stop lamp switch for inspection and necessary adjustments.