Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the battery negative cable.





2. Remove the washer solvent container retaining nuts.
3. Lift the washer solvent container from the left wheelhouse.
4. Disconnect the electrical connections and the washer hose from the container.
5. Plug the washer pump outlet.





6. Disconnect the electrical connector (1) from the brake fluid level sensor.





7. Remove the nuts securing the master cylinder to the brake booster.
8. Remove the master cylinder from the brake booster without disconnecting the brake pipes and position the master cylinder aside.





9. Disconnect the brake booster vacuum hose from the booster check valve.
10. Remove the instrument panel lower trim panel.





11. Remove the retainer, washer, brake pedal pin, and brake booster pushrod from the brake pedal.





12. Remove the screw (3) from the telescoping ~ column motor mounting bracket (5), if equipped.
13. Position the motor assembly to the right of the steering column.





14. Remove the brake booster mounting nuts and washers from the booster studs.

Important: The brake booster is retained to the cowl with push-on nuts.
15. In order to remove the booster from the cowl, perform the following steps:
^ In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
^ Pull the booster straight out.

16. Remove the brake booster and seal from the cowl,
17. Inspect the booster seal and sealing surfaces for damage. Replace the seal if necessary.

Installation Procedure





1. Install the seal and brake booster to the front of dash.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install brake booster mounting nuts and washers to the booster studs.
Tighten the brake booster mounting nuts to 27 Nm (19 ft. lbs.).





3. Install the brake booster pushrod, brake pedal pin, washer, and retainer to the brake pedal. Verify proper engagement of the retainer to the brake pedal by rotating the retainer.
4. Reposition the telescoping column motor assembly to the steering column, if equipped.





5. Install the screw (3) to the motor mounting bracket (5).
Tighten the screw to 7 Nm (62 inch lbs.)
6. Install the instrument panel lower trim panel.





7. Connect the brake booster vacuum hose to the brake booster check valve.





8. Install the master cylinder to the brake booster.
9. Install the master cylinder mounting nuts.
Tighten the master cylinder mounting nuts to 29 Nm (21 ft. lbs.).





10. Connect the electrical connector (1) to the brake fluid level sensor.





11. Connect the electrical connector and the washer hose to the washer solvent container.
12. Install washer solvent container to the wheelhouse.
13. Install the washer solvent container retaining nuts.
Tighten the washer solvent container retaining nuts to 7.5 Nm (66 inch lbs.).
14. Connect the battery negative cable.
15. Program the transmitters.