Vacuum Brake Booster: Service and Repair

^ Tool Required:
- J 22805-01 Power Brake Booster Holder

CAUTION: When replacing the power brake booster, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.

NOTICE: Inspect locking flanges on brake booster and mounting plate. Replace the brake booster and mounting plate if the locking flanges are bent or damaged.

REMOVE OR DISCONNECT
1. Engine acoustic cover.
2. ABS hydraulic modulator/master cylinder.
3. Transmission fluid filler tube.
4. EGR heat shield.
5. Vacuum hose from brake booster.





NOTICE: When disconnecting the pushrod from brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.

NOTICE: Do not attempt to remove booster until pushrod is disconnected from the brake pedal.

6. Brake booster pushrod from brake pedal.
7. Attach J 22805-01 to brake booster with nuts.
- Tighten nuts to 27 Nm (20 ft. lbs.).





8. Unlock brake booster from front of dash as shown.
9. Use a flat-bladed tool to pry locking tab on booster out of locking notch on mounting flange. At the same time turn the booster counterclockwise with a wrench on J 22805-01.
10. Brake booster.

Important: Take care not to damage insulator boot mounted on the front of dash when pulling pushrod eye through hole.

INSTALL OR CONNECT

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. the manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.





1. Attach J 22805-01 to new brake booster with nut
- Tighten nuts to 27 Nm (20 ft. lbs.).
2. Position brake booster on cowl, slightly counterclockwise from final installation position, so that locking flanges on brake booster and mounting plate engage.

Important: Take care not to damage or dislodge insulator boot when passing pushrod eye through the hole.

3. Turn brake booster clockwise with wrench on J 22805-01.








- It is not necessary to use a flat-bladed tool on locking tab to install brake booster. When correctly installed, locking tab will slide up flange and snap in locking notch.

Important: Make sure locking tab and flanges are in the fully engaged position.

4. Brake booster pushrod to brake pedal.
5. Vacuum hose to brake booster.
6. EGR heat shield.
7. Transmission fluid filler tube.
8. ABS hydraulic modulator/master cylinder.
9. Engine acoustic cover.