Vacuum Brake Booster: Service and Repair

1. Unfasten master cylinder from brake booster and move forward, leaving brake lines attached.
2. Remove vacuum hose connection nut from intake manifold.
3. Disconnect vacuum hose from brake booster.
4. Remove windshield washer reservoir, then the brake lamp switch and brake pedal spring.
5. Remove pushrod pin retainer and the pin.
6. On models less power steering, remove brake pedal bracket nuts from dash panel.
7. On models with power steering, remove lower mounting screw located behind brake lines.

Fig. 3 Brake booster assembly:

8. On all models, tilt brake servo upward and remove booster and support bracket from dash panel.
9. Remove two-piece support bracket from booster.

Fig. 4 Brake booster pushrod adjustment:

10. Reverse procedure to install, noting the following:
a. If adjustment sleeve was removed from booster, install sleeve so that dimension ``A,'' measures 11 inches.
b. Torque booster support bracket attaching bolts to 16 ft.lbs
c. Torque booster-to-dash panel attaching bolts to 16 ft.lbs
d. Torque booster-to-master cylinder attaching bolts to 13 ft.lbs
e. Torque vacuum hose connection nut to 11 ft.lbs.