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Today I went to stop for a red light and found out that the pedal was rock hard, no indication in previous stops. After missing the car in front of me and finally getting it stopped in the grass with the E brake, it left me with the question what the .... ? I shut off the van and when I started it back up the pedal was back to normal (slightly more spongy). Any suggestions on were to start? I was thinking of brake booster, if this is it, how involved is this job?
Sounds like the booster. The only problem is that it seem like an intermitent problem. I would replace the booster and master cylinder. Most auto parts stores will not warranty the booster unless you replace the master cylinder also. Not a bad idea, really. Not too bad of a job, just make sure you follow the instructions and bench bleed the master. Install it and bleed the system and go to town and celebrate. I would say it's about an hour and a half job, including lunch. Have fun.
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