Vacuum Brake Booster: Service and Repair

Booster Assembly:

Tool required:
J-22805-01 Booster holder

Remove or Disconnect

Booster Assembly Removal/Installation:

1. ABS hydraulic modulator assembly, if equipped.
2. Nuts (33) and master cylinder (31) from booster (32).
3. Scribe a mark on front and rear housings (6 and 7).
^ This is to be used as a reference point to assure that the front and rear housings are not accidentally separated when removing the booster.

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

Disengaging Or Engaging Booster Mounting Flange:

4. Unlock booster (32) from front of dash as shown in the illustration.
5. Attach J-22805-01 (34) to booster (32) with nuts (33).

Tighten
^ Nuts to 27 Nm (20 lbs ft).

6. Use a screwdriver (35) to pry locking tab (36) on booster out of locking notch (37) on mounting flange. At the same time turn the booster counterclockwise with a wrench (38) on J-22805-01 (24).

NOTICE: Do not attempt to remove booster (32) until pushrod (29) is disconnected from the brake pedal.

7. Booster push rod (29) from brake pedal.
8. Remove booster (32).
^ Take care not to damage insulator boot mounted on the front of dash when removing/installing pushrod (29) eye through hole.

Install or Connect

1. Attach J-22805-01 (34) to booster (32) with nuts (33).

Tighten
^ Nuts to 27 Nm (20 lbs ft).

2. Position booster (32) on cowl, slightly counter-clockwise from final installation position, so that locking flanges on booster and mounting plate engage.
^ Take care not to damage or dislodge insulation boot when passing pushrod (29) eye through hole.
3. Booster pushrod (29) to brake pedal.
4. Turn booster (32) clockwise with wrench (38) on J-22805-01 (34).
^ It is not necessary to use screwdriver (35) on locking tab (36) as shown to install booster. When correctly installed, locking tab will slide up flange and snap in locking notch (37).

Important
^ Make sure locking tab (36) is fully engaged in locking notch (37).

5. Master cylinder (31) to booster (32) with attaching nuts (33)

Tighten
^ Nuts to 27 Nm (20 lbs ft).

6. ABS hydraulic modulator assembly, if equipped.

Adjust
^ Stoplamp switch.