RHD
Vacuum Brake Booster Replacement (RHD)
^ Tools Required
- J 22805-B Brake Booster Holder
Removal Procedure
1. Remove the left closeout/insulator.
2. Remove the vacuum brake booster pushrod retaining clip (4).
3. Remove the vacuum brake booster pushrod (3) from the brake pedal assembly.
4. If equipped with a cross vehicle brace, remove the cross vehicle brace.
5. Remove the master cylinder from the vacuum brake booster and position the master cylinder aside.
Important: It is not necessary to disconnect the brake pipes from the master cylinder.
6. Remove the air inlet grille panel, to gain access to the vacuum brake booster locking tab.
7. Remove the coolant surge tank inlet hose from the surge tank.
Important: It is not necessary to drain the coolant or disconnect the surge tank outlet hose from the coolant surge tank.
8. Remove the coolant surge tank bolts and position the coolant surge tank out of the way.
9. Install the coolant surge tank inlet hose to the coolant surge tank to prevent coolant loss.
10. Disconnect the vacuum brake booster check valve from the vacuum brake booster and position out of the way.
11. Attach the J 22805-B to the vacuum brake booster using the master cylinder retaining nuts.
12. Unlock the booster from the front of the cowl. Use a flat bladed tool to depress the vacuum brake booster locking tab (1) out of the cowl mounting flange, while turning the vacuum brake booster counterclockwise with a ratchet on the J 22805-B (2).
13. Carefully remove the vacuum brake booster from the cowl mounting flange.
14. Support the vacuum brake booster.
15. Carefully push the vacuum brake booster foam filter (1) in enough to access the vacuum brake booster retaining clip (2).
16. Carefully lift the longer leg of the retaining clip (2) upward.
17. Carefully remove the vacuum brake booster pushrod (3) from the vacuum brake booster.
Installation Procedure
Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.
Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
1. Carefully install the vacuum brake booster to the vacuum brake booster pushrod (3).
2. Carefully push the vacuum brake booster pushrod on to the vacuum brake booster until the long leg of the retaining clip seats into the machined groove of the pushrod.
Important: Ensure that the long leg of the retainer clip is in the machined groove of the pushrod (3).
3. Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.
4. Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
Important: Ensure that the locking tab and the flanges are in the fully engaged position.
5. Remove the J 22805-B (2) from the installed vacuum brake booster.
6. Reposition and connect the vacuum hose and check valve assembly to the vacuum brake booster.
7. Remove the coolant surge tank inlet hose from the coolant surge tank.
8. Install the coolant surge tank.
9. Install the air inlet grille panel.
10. Install the master cylinder to the vacuum brake booster.
11. If equipped with a cross vehicle brace, install the cross vehicle brace.
12. Install the vacuum brake booster pushrod (3) to the brake pedal assembly.
13. Install the vacuum brake booster pushrod retaining clip (4).
14. Install the left closeout/insulator panel.