Here's a general outline of the process. This is NOT a comprehensive guide and may vary slightly depending on your specific Intrepid model. Always consult a repair manual specific to your year and model for detailed instructions and torque specifications:
1. Safety First:
* Disconnect the negative battery terminal. This is crucial to prevent electrical shorts.
* Have a helper. Many steps are easier with an extra set of hands.
* Gather your tools: You'll need sockets (various sizes), wrenches, pliers, a brake bleeder kit, possibly a vacuum pump for the new booster, and a new brake booster (ensure it's the correct one for your vehicle).
2. Preparation:
* Drain some brake fluid: Open the brake fluid reservoir and remove some fluid to make room for any that might overflow during the process. Use a clean container.
* Locate the brake booster: It's typically located behind the brake pedal, under the dashboard. You might need to remove some trim panels or parts of the dashboard to access it. Refer to a repair manual for specifics.
3. Removal:
* Disconnect the vacuum hose: Carefully disconnect the vacuum hose from the brake booster.
* Disconnect the brake lines: This requires careful attention. You'll likely need to use a flare nut wrench to avoid damaging the lines. Be prepared for brake fluid to leak. Have absorbent cloths ready.
* Disconnect the pushrod: This connects the booster to the master cylinder. Take note of its position to ensure correct reassembly.
* Unbolt the brake booster: There are typically several bolts securing the booster to the firewall. Remove them carefully.
* Remove the brake booster: With everything disconnected, carefully remove the brake booster.
4. Installation:
* Install the new brake booster: Reverse the removal process to install the new booster.
* Reconnect the pushrod: Ensure it's correctly aligned.
* Reconnect the brake lines: Tighten the flare nuts securely.
* Reconnect the vacuum hose:
* Bleed the brakes: This is crucial to remove air from the brake lines. Use a brake bleeder kit and follow the proper bleeding procedure (typically starting with the furthest wheel from the master cylinder).
* Refill the brake fluid reservoir: Check the fluid level and top it off as needed.
5. Testing:
* Check for leaks: Inspect all connections for leaks.
* Test the brakes: Carefully test the brakes several times. If the pedal feels spongy or the brakes are weak, there's likely air in the system, and you need to bleed the brakes again.
Important Considerations:
* Vacuum Testing: Some mechanics use a vacuum pump to test the new booster before installation, ensuring it's functioning correctly.
* Repair Manual: A repair manual specific to your 1999 Dodge Intrepid is invaluable for this repair. It will provide detailed diagrams and instructions.
* Professional Help: If you are uncomfortable performing this repair, or if you encounter unexpected difficulties, take your vehicle to a qualified mechanic. Brake system failure is extremely dangerous.
This is a complex procedure. This information is for general guidance only and does not replace professional advice or a dedicated repair manual. Proceed with caution and at your own risk.
