Vacuum Brake Booster: Service and Repair

REMOVAL PROCEDURE
1. Remove the master cylinder attaching nuts (6).

Important: The booster can be removed from the vehicle without removing or disconnecting the master cylinder. However, if both the booster and master cylinder are to be removed, remove the master cylinder first; refer to Master Cylinder.





Disconnect the booster vacuum hose (1) from the vacuum check valve (2).
2. Remove the master cylinder (7) from the booster (2).





3. Move the master cylinder (7) forward just enough to clear the studs on the booster. This will flex the brake pipes slightly, it's important to be careful not to bend or distort the pipes.
4. Remove the acoustical barrier from the booster studs (under I/P).
5. Remove the booster attaching nuts (4).
6. Remove the booster pushrod from the brake pedal.
7. Tilt the entire booster slightly to work the pushrod off the pedal clevis pin without putting undue side pressure on the pushrod.
8. Remove the booster from the vehicle.
9. Remove the gasket.





INSTALLATION PROCEDURE
1. Connect the gashes to the booster.
2. Connect the booster (2) to the vehicle.
3. Connect the booster pushrod to the brake pedal.
4. Tilt the entire booster slightly to work the pushrod onto the pedal clevis pin without putting undue side pressure on the pushrod.
5. Install the booster attaching nuts (4).

^ Tighten the attaching nuts to 21 Nm (15 ft. lbs.).

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

6. Install the acoustical barrier onto the booster studs (under I/P).
7. Connect the master cylinder (7) to the booster (2).
8. Install the master cylinder attaching nuts (6).
^ Tighten the attaching nuts to 27 Nm (20 ft. lbs.).





9. Connect the booster vacuum hose (1) to the vacuum check valve (2).