Vacuum Brake Booster: Service and Repair

Brake Booster

Brake Booster:

Removal and Installation
1. Disconnect the battery ground cable.
2. Disconnect the brake fluid level sensor electrical connector.
3. Disconnect the brake booster check valve.
4. Remove the 2 brake master cylinder nuts.
^ To install, tighten to 28 Nm (21 ft. lbs.).
5. Disconnect the wiring harness bracket and position it aside.





6. Pull the brake master cylinder forward and position it aside.
7. Remove the pin-type retainers and the instrument close-out panel.

8. CAUTION: The stop lamp switch and the speed control deactivator switch must be removed prior to removing the brake pedal and bracket, brake booster and associated mounting fasteners or damage to the switches can occur.

Disconnect the stop lamp switch electrical connector.
9. Remove the cover and the self-locking pin.
10. Remove the stop lamp switch from the brake booster push rod and brake pedal.
11. If equipped, remove the speed control deactivator switch.
12. Remove the brake booster push rod retaining pin cover, retaining pin, washer, bushing and switch.
^ Slide the booster push rod off the pedal pin.
13. Remove the nuts and the power brake booster.
^ To install, tighten to 28 Nm (21 ft. lbs.).

14. CAUTION: Do not install the speed control deactivator switch until installation of the brake booster, brake pedal and bracket are complete. The brake pedal arm must be secured to the brake booster push rod and in the at-rest position prior to switch installation. Failure to follow these instructions can result in incorrect adjustment or damage to the switch.

CAUTION: Do not press, pull or otherwise move the brake pedal while installing the speed control deactivator switch. Failure to follow these instructions can result in incorrect adjustment or damage to the switch.

CAUTION: The brake switch must be positioned with the closed hole away from the brake pedal arm and the open hole toward the brake pedal arm.

NOTE: The brake booster input rod must be correctly oriented during installation.

To install, reverse the removal procedure.