Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement (3.9L)

Removal Procedure




1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).
2. Disconnect the electrical connector from the exhaust gas recirculation (EGR) valve (1).
3. Disconnect the engine harness clips (3).
4. Position the harness to the side.




5. Disconnect the brake fluid level indicator switch electrical connector (1).




6. Remove the master cylinder nuts.
7. Remove the master cylinder.
Position the master cylinder aside and support with heavy mechanics wire or equivalent.




8. Disconnect the power vacuum brake booster check valve and hose (2).
9. Remove the left knee bolster. Refer to Driver Knee Bolster Replacement (Driver Knee Bolster Replacement).
10. Remove the steering column support mounting bolts. Refer to Steering Column Replacement (Steering Column Replacement).
11. Lower the steering column and support with heavy mechanics wire.
12. Disconnect the brake pedal position sensor electrical connector.




13. Remove the bolt and the power vacuum brake booster pushrod retainer clip (2).
14. Remove the vacuum brake booster pushrod spacer (3).




15. Remove the power vacuum brake booster nuts (1).




16. Remove the power vacuum brake booster.

Note: Do not reuse the power vacuum brake booster gasket if damaged.

17. Remove the power vacuum brake booster gasket.
Inspect the power vacuum brake booster for damage and replace, if necessary.

Installation Procedure




1. Install the power vacuum brake booster gasket.
2. Install the power vacuum brake booster.




3. Install the power vacuum brake booster pushrod to the brake pedal.
4. Install the spacer (3).
5. Install the retaining clip (2).

Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the power vacuum brake booster pushrod retaining clip bolt and tighten to 7 Nm (62 lb in)




7. Install the power vacuum brake booster nuts (1) 30 Nm (22 lb ft).
8. Connect the brake pedal position sensor electrical connector.




9. Install the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
10. Install the steering column. Refer to Steering Column Replacement (Steering Column Replacement).
11. Install the knee bolster panel. Refer to Driver Knee Bolster Replacement (Driver Knee Bolster Replacement).




12. Install the power vacuum brake booster check valve and hose (2).




13. Install the brake fluid level indicator switch electrical connector (1).




14. Position the engine wiring harness (2).
15. Connect the electrical connector for the EGR valve (1).
16. Connect the engine harness clips (3).
17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Intake Manifold Cover Replacement).
18. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration ().