Power Brake Booster Replacement

Removing And Installing Power Brake Booster (Typical):

Brake Booster Vacuum Hose (3800 VIN K):

REMOVE OR DISCONNECT
1. Hood rear seal.
2. Air inlet screen.
3. Brake booster vacuum hose clamp (31) and vacuum hose (30) from check valve (4).
4. Master cylinder nuts (1) attaching master cylinder (2) to brake booster (3).
5. Master cylinder (2) from brake booster (3). Move master cylinder (2) forward and toward driver's side to provide clearance for booster (3). This will flex brake pipes slightly. Take care not to bend or distort brake pipes.
6. Left side instrument panel insulator.
7. Brake pedal nuts (5) attaching brake booster (3) to brake pedal with bracket (20).
8. Loosen clutch master cylinder nuts (41). On vehicles equipped with manual transmissions.
9. Brake booster pushrod (6) from brake pedal lever pin.
a. From inside vehicle, remove brake pedal pushrod retainer (16) and pushrod washer (15).
b. Tilt entire brake booster (3) slightly to work brake booster pushrod (6) off brake pedal pin without putting undue side pressure on pushrod (6).
10. Power brake booster (3) from vehicle.

INSTALL OR CONNECT
1. Power brake booster (3) onto vehicle.
2. Brake booster pushrod (6) to brake pedal lever pin.
a. Tilt entire brake booster (3) slightly to work brake booster pushrod (6) on to brake pedal pin without putting undue side pressure on pushrod (6).
b. From inside vehicle, install brake pedal pushrod washer (15) and pushrod retainer (16).
3. Brake pedal nuts (5). Tighten Brake pedal nuts (5) to 20 Nm (15 ft. lbs.) in sequence:
- Inboard upper
- Outboard lower
- Outboard upper
- Inboard lower
4. Tighten clutch master cylinder nuts (41) on vehicles equipped with manual transmissions. Tighten Clutch master cylinder nuts (41) to 27 Nm (20 ft. lbs.).
5. Master cylinder (2) to brake booster (3).
6. Master cylinder nuts (1) attaching master cylinder (2) to brake booster (3). Tighten Brake master cylinder nuts (1) to 29 Nm (21 ft. lbs.).
7. Vacuum hose (30) and clamp (31) to check valve (4).
8. Left hand instrument panel insulator.
9. Air inlet screens.