Vacuum Brake Booster: Service and Repair

Servo Assembly

Service Repair No - 70.50.01

Removal
1. Remove engine compartment bulkhead closing panel.
2. Remove brake master cylinder.





3. Disconnect vacuum pipe from servo.
4. Remove nut securing alarm sounder to mounting bracket and move aside.





5. Remove bolt securing pre-charge pump bracket to body.
6. Release pump from rubber mounting.
7. Disconnect multiplug.
8. Remove pump.
9. Remove shroud.





10. Remove clip and clevis pin securing servo push rod to brake pedal.
11. Remove and discard 2 nuts securing brake servo.
12. Remove brake servo.

Installation
1. Fit new gasket to brake servo and fit servo.

CAUTION: RHD models: When fitting the servo, ensure air suspension pipe is not trapped behind it.

2. Fit new nuts securing brake servo to pedal bracket and tighten to 26 Nm (19 ft. lbs.).

CAUTION: Nuts securing brake servo to pedal bracket must be re-torqued after 20 minutes have elapsed.

3. Clean clevis pin and smear with grease.
4. Align push rod, fit clevis pin and secure with clip.
5. Fit shroud.
6. Locate pre-charge pump to mounting rubbers.
7. Connect multiplug.
8. Fit bolt securing pre-charge pump and tighten to 8 Nm (6 ft. lbs.).
9. Position alarm sounder to bracket, fit nut and tighten to 8 Nm (6 ft. lbs.).
10. Connect vacuum pipe.
11. Fit brake master cylinder.
12. Fit bulkhead closing panel.