Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

1. Turn the ignition switch to the OFF position.
2. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
4. Disconnect the brake fluid level indicator switch electrical connector.
5. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).




6. Disconnect the vacuum brake booster check valve (1) from the power vacuum brake booster and position aside.




7. Remove the master cylinder nuts (1).
8. Without disconnecting the brake pipe fittings, remove the master cylinder and position aside.
Secure the master cylinder in an upright position with heavy mechanics wire or equivalent.
9. Remove the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair).




10. Remove the brake booster pushrod clevis pin retainer (1).




11. Remove the brake booster pushrod clevis pin (1).




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

Note: The power vacuum brake booster is retained to the cowl with push-on nuts during assembly.




13. Remove the power vacuum brake booster (1).
Move the power vacuum brake booster from side-to-side to release the booster studs from the push-on nuts.
14. Remove the power vacuum brake booster gasket (2).
Inspect the gasket for damage and replace, if necessary.

Installation Procedure




1. Install the power vacuum brake booster (1) and the gasket (2) to the vehicle.

Caution: Refer to Fastener Caution (Fastener Caution).




2. Install the power vacuum brake booster nuts (1) and tighten to 27 Nm (20 lb ft).




3. Install the brake booster pushrod clevis pin (1) to the brake pedal and the power vacuum brake booster pushrod.




4. Install the brake booster pushrod clevis pin retainer (1).
Rotate the clevis pin retainer to ensure it is fully engaged in the clevis pin groove.
5. Install the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair).




6. Install the master cylinder to the power vacuum brake booster.
7. Install the master cylinder nuts (1) and tighten to 18 Nm (13 lb ft).




8. Connect the vacuum brake booster check valve (1) to the power vacuum brake booster.
9. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
10. Connect the brake fluid level indicator switch electrical connector.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).