Chrysler Caravan/Voyager/Town and Country 1996-1999

Power Brake Booster

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8



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Fig. Fig. 1: The air inlet resonator must be removed to allow room for the booster



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Fig. Fig. 2: The battery tray must also be removed for clearance



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Fig. Fig. 3: Removing the air inlet resonator (3.0L engine)

  1. Disconnect the negative battery cable.
  2.  
  3. With the engine not running, pump the brake pedal until a firm pedal is achieved (approximately 4-5 strokes).
  4.  
  5. Remove the battery from the vehicle.
  6.  
  7. Remove the air inlet resonator/air cleaner assembly from the engine compartment.
  8.  
  9. If equipped with speed control, disengage the wiring harness connector from the speed control servo. Disconnect the vacuum lines from the speed control servo and vacuum reservoir on the battery tray.
  10.  
  11. Remove the bolt securing the speed control servo bracket to the battery tray. Move the bracket forward to unhook it from the battery tray and remove.
  12.  
  13. Remove the battery tray from the vehicle.
  14.  
  15. On 3.3L and 3.8L engines, perform the following:
    1. Remove the EGR valve and vacuum transducer as an assembly from the intake manifold.
    2.  
    3. Remove the 2 bolts mounting the throttle body to the intake manifold and the clip securing the wiring harness to the throttle cable bracket. Then remove the throttle body and throttle cable bracket as an assembly from the intake manifold.
    4.  

  16.  
  17. Disengage the wiring harness connector from the brake fluid level sensor in the master cylinder fluid reservoir.
  18.  
  19. To prevent any dirt particles from falling into the vacuum booster, thoroughly clean the master cylinder and power brake booster using MOPAR® Brake Parts Cleaner, or equivalent.
  20.  
  21. Remove the clip attaching the drain hose for wiper module to the brake tube at the master cylinder. Remove the drain hose from the windshield wiper/motor module assembly.
  22.  

It is not necessary to disconnect the brake lines from the master cylinder when removing the master cylinder from the vacuum booster.

  1. Remove the 2 nuts that secure the master cylinder to the power booster.
  2.  
  3. Remove the master cylinder and brake tubes as an assembly from the vacuum booster. When the master cylinder is removed, lay it out of the way on top of the left motor mount.
  4.  
  5. Disconnect the vacuum hose from the check valve located on the power booster. Do not remove the check valve.
  6.  



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Fig. Fig. 4: On 3.3/3.8L engines, the throttle body ...



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Fig. Fig. 5: ... and the EGR valve must also be removed to allow clearance for the booster to be lifted from the engine compartment



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Fig. Fig. 6: After the necessary components are removed for clearance, remove the master cylinder

  1. Locate the vacuum booster input rod-to-brake pedal attachment under the instrument panel. Position a small, flat-bladed prying tool between the center tang on the power booster input rod-to-brake pedal pin retaining clip.
  2.  
  3. Rotate the pry tool enough to allow the retaining clip center tang to pass over the end of the brake pedal pin. Then remove the clip from the brake pedal pin. Discard the clip, it is not to be reused. It must be replaced with a new retaining clip.
  4.  
  5. Remove the 4 nuts attaching the power booster to the dash panel. These nuts are accessible from under the instrument panel, in the area of the steering column and pedal bracket assembly.
  6.  
  7. From the engine compartment, slide the power booster forward until its mounting studs clear the dash panel. Then tilt the power booster up and toward the center of the vehicle to remove.
  8.  

To install:
  1. Place the power booster in position against the dash panel.
  2.  
  3. Install the 4 power booster mounting nuts and tighten to 21 ft. lbs. (29 Nm).
  4.  
  5. Using Lubriplate®, or an equivalent, coat the surface of the brake pedal pin where it contacts the power booster input rod.
  6.  
  7. Connect the power booster input rod to the brake pedal pin and secure with a new retaining clip.
  8.  
  9. Connect the vacuum hose to the power booster check valve.
  10.  
  11. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange and install a NEW vacuum seal.
  12.  
  13. Place the master cylinder back into position against the power booster, aligning the push rod of the booster unit with the master cylinder piston. Install and tighten the master cylinder mounting nuts to 18 ft. lbs. (25 Nm).
  14.  
  15. Connect the wiper module drain hose to the bottom of the windshield wiper/motor module assembly. Loosely install the tie strap attaching the wiper module drain hose to the brake line at the master cylinder.
  16.  
  17. Plug the wiring harness connector into the brake fluid level sensor on the master cylinder fluid reservoir.
  18.  
  19. On 3.3L and 3.8L engines, perform the following:
    1. Install the throttle body and throttle cable bracket assembly onto the intake manifold. Install the clip securing the wiring harness to the throttle cable bracket.
    2.  
    3. Install the EGR valve and vacuum transducer assembly onto the intake manifold.
    4.  

  20.  
  21. Install the battery tray. Tighten the mounting fasteners to 10 ft. lbs. (14 Nm).
  22.  
  23. If equipped with speed control, install the speed control servo and bracket onto the battery tray. Tighten the bracket mounting bolt.
  24.  



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Fig. Fig. 7: Disconnect the booster from the pedal by removing the retaining clip from the pin



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Fig. Fig. 8: The retaining clip can be removed by lifting the curved tab with your thumb and pushing sideways

  1. If equipped with speed control, install the wiring harness connector to the speed control servo. Then connect the vacuum lines onto the speed control servo and vacuum reservoir on the battery tray.
  2.  
  3. Install the air inlet resonator/air cleaner assembly into the engine compartment. Securely tighten the hose clamps.
  4.  
  5. Install the battery.
  6.  
  7. Connect the positive battery cable, then the negative battery cable.
  8.  
  9. Check the operation of the stop lamp switch and adjust, if necessary.
  10.  

 
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