1999 Dodge Caravan Brake Booster

Tiny
MRPERRO
  • MEMBER
  • 1999 DODGE CARAVAN
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 145,288 MILES
What is the process to remove and replace the brake booster?
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Friday, June 18th, 2010 AT 3:37 PM

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Tiny
MERLIN2021
  • EXPERT
Removal (3.3L & 3.8L V6) 1. Release vacuum from power brake booster by pumping brake pedal several times with engine off until brake pedal becomes firm. Disconnect battery cables from battery. Remove battery guard and battery. Remove air inlet resonator with hoses attached from throttle body and air cleaner housing. 2. On models with cruise control, disconnect electrical connector at cruise control servo. Disconnect vacuum hoses from cruise control servo and vacuum reservoir on battery tray. Remove cruise control servo mounting bracket-to-battery tray bolt. Slide mounting bracket forward and unhook from battery tray. Remove mounting bracket and cruise control servo. 3. On all models, remove bolts/nuts and battery tray. Disconnect electrical connectors at EGR transducer and throttle body. Remove bolts and throttle body with throttle cable bracket from intake manifold. 4. Disconnect electrical connector at brake fluid level sensor located on master cylinder fluid reservoir. Remove wiring harness bracket from studs on driver's side strut tower. 5. Clean master cylinder-to-power brake booster area to prevent dirt particles from falling into power brake booster. Remove clip attaching drain hose on brakeline at master cylinder. Remove drain hose from windshield wiper module. 6. Remove master cylinder-to-power brake booster nuts and slide master cylinder from power brake booster with brakelines attached and secure aside. Remove EGR valve with EGR transducer as an assembly from intake manifold. Disconnect vacuum hose from check valve on power brake booster. DO NOT remove check valve from power brake booster. 7. Remove power brake booster rod-to-brake pedal pin retaining clip by positioning a small screwdriver between center tang on retaining clip. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Pull retaining clip from brake pedal pin. Discard retaining clip. Disconnect brake booster rod from brake pedal pin. 8. On models with ABS, remove mounting nuts securing Controller Anti-Lock Brake (CAB) on power brake booster mounting studs, near brake pedal. Lay CAB aside with electrical connector still installed on CAB. 9. On all models, remove power brake booster-to-firewall nuts located below dash panel, near steering column and brake pedal bracket. From engine compartment, slide power brake booster forward until booster clears studs, and then tilt upward and toward center of vehicle to remove. 10. Remove master cylinder-to-power brake booster vacuum seal from groove on mounting flange of master cylinder by pulling vacuum seal from master cylinder. DO NOT pry vacuum seal from master cylinder. CAUTION: DO NOT pry master cylinder-to-power brake booster vacuum seal from master cylinder by inserting sharp tool between master cylinder and vacuum seal. CAUTION: DO NOT attempt to disassemble power brake booster. Power brake booster is serviced only as a complete unit. Master cylinder-to-power brake booster vacuum seal must always be replaced. DO NOT reuse vacuum seal. Ensure vacuum seal is squarely installed in groove on mounting flange of master cylinder.
Installation 1. To install, reverse removal procedure. Ensure heater hoses are not caught between dash panel and power brake booster when installing power brake booster. 2. Use NEW retaining clip and NEW master cylinder-to-power brake booster vacuum seal. DO NOT reuse retaining clip or vacuum seal. Coat bearing surface of brake pedal pin with grease before installing brake booster rod on brake pedal pin. 3. Ensure NEW master cylinder-to-power brake booster vacuum seal is squarely installed in groove on mounting flange of master cylinder before installing master cylinder. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS table. Check stoplight operation. It may be necessary to adjust stoplight switch. See STOPLIGHT SWITCH under ADJUSTMENTS.
STOPLIGHT SWITCH 1. Stoplight switch is located in mounting bracket near top of brake pedal. Rotate stoplight switch counterclockwise 30 degrees and remove switch from mounting bracket. Disconnect electrical connector from stoplight switch. 2. Pull plunger on stoplight switch outward until plunger has ratcheted outward to fully extended position. Fully depress brake pedal. Install stoplight switch in mounting bracket so index tab on stoplight switch aligns with slot in mounting bracket. 3. With stoplight switch fully seated in mounting bracket, rotate stoplight switch 30 degrees to lock stoplight switch in mounting bracket. Reinstall electrical connector on stoplight switch. 4. Gently pull brake pedal upward toward stoplight switch until brake pedal stops moving. This will ratchet plunger on stoplight switch backward to correct operating position. CAUTION: DO NOT use excessive force when pulling brake pedal upward, or stoplight switch may be damaged.
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Friday, June 18th, 2010 AT 3:41 PM
Tiny
EDDIERNORTON
  • MEMBER
I recently replaced to booster on a 98 Grand Caravan. The procedure provided by merlin2021 above seems to follow the steps in the service manual. One problem I ran into was that there was a heater hose in the way. I was able to wrestle the old booster out but the hose prevented clearance to get the new one in. Unable to get the heater hose disconnected (without damage), I solved this problem by using two strap clamps (http://www.amazon.com/Jorgensen-PONY-15-BAND-CLAMP/dp/B0055KTKU6/ref=sr_1_2?ie=UTF8&qid=1326330975&sr=8-2)
I threaded one through the hole in the booster arm and around the booster and tightened it to compress the booster arm. I wrapped the second one around the heater hose and through a hole in the radiator cowl and tightened it to pull the heater hose out of the way. Once I got the booster arm through the firewall I released and removed the clamp holding it. Was still tight but after some fiddling and twisting the 4 mounting bolts finally found the holes in the firewall.
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Thursday, January 12th, 2012 AT 1:24 AM
Tiny
MONIQUETRIANA
  • MEMBER
Hello,
I have decided to do this myself and have followed all steps. When taking out booster there is a metal hose that sticks up right behind where the throttle body was. It is not removable and would not allow me to completely take out booster. I ripped it out breaking plastic on old booster. That metal hose being there will not allow me to install new one, there is no room with the metal portion of the inside on the right sticking out. I don't know what to do because it is physically impossible to get it back in such a tight fit with that metal hose there. Idisconnected the rubber hose that came off but still no room. I have pictures I'd needef. Please help!
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Tuesday, September 29th, 2015 AT 2:21 PM

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