Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure

1. Remove the air cleaner assembly.
2. Disconnect and position aside the underhood electrical center from the bracket.
3. Remove the underhood electrical center; bracket.
4. Remove the EGR valve.







5. Remove the master cylinder (2) from the hydraulic brake booster (1). Careful not lose or dislodge the insulator between the booster and the front of the dash.







6. Disconnect the vacuum hose and the vacuum brake booster check valve (1) from the booster as an assembly.







7. Remove the left Closeout/Insulator Panel.
8. Remove the booster retaining nuts (2).







9. Disconnect the booster pushrod (1) from the brake pedal (2).
Tilt the vacuum brake booster slightly in order to work the booster pushrod off the pedal clevis pin. Do not apply excessive side pressure on the pushrod.

10. Remove the booster from the vehicle.



Installation Procedure







1. Install the booster to the vehicle.
2. Install the booster pushrod (1) to the brake pedal (2).
Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the pedal clevis pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.

Notice: Refer to Fastener Notice in Service Precautions.
Fastener Notice







3. Install the booster retaining nuts (2).
- Tighten the booster to brake pedal retaining nuts to 27 Nm (20 ft. lbs.).

4. Install the left Closeout/Insulator Panel.







5. Connect the vacuum hose and the vacuum brake booster check valve (1) to the booster as an assembly.







6. Install the master cylinder (2) to the booster (1).
7. Install the master cylinder.
8. Install the EGR valve.
9. Install the underhood electrical center bracket.
10. Position back and connect the underhood electrical center.
11. Install the cleaner assembly.