Vacuum Brake Booster: Service and Repair

1. Remove master cylinder as previously described.
2. Depress brake pedal and clamp master cylinder pushrod.
3. Adjust connector to limit amount of protrusion of brake pushrod from booster, then again depress brake pedal and adjust clamp.
4. Remove connector.
5. Remove cover and the booster attaching bolts.
6. If applicable, remove brake line for right front wheel from holder on cross wall and carefully push toward engine, then route hose for clutch master cylinder and electric wires out of way.
7. Remove booster, removing lower section of air cleaner as necessary to facilitate removal.
8. If necessary, replace gasket between booster and firewall. Use 2 mm thick gasket for ten inch booster and a 4 mm or two 2 mm gaskets for nine inch booster.
9. Install booster, ensuring caps fit properly above control housing.
10. Install brake pressure regulator and the master cylinder, replacing seal between booster and master cylinder.
11. Mount brake pushrod and connector on brake pedal.
12. Pull back brake pedal arm to stop, then loosen locknut on pushrod and adjust pushrod until play of at least .4 inch (10 mm) is obtained.
13. Tighten locknut on pushrod.
14. Bleed brake/clutch system.