Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER REMOVAL/INSTALLATION

NOTE:Hybrid vehicle shown. Conventional vehicles similar.










Removal/Installation

All vehicles

CAUTION:Do not service the brake pedal or brake booster without first removing the brake pedal position (BPP) switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.
1. Remove the brake pedal position (BPP) switch. See Service and Repair.

NOTE:The booster push rod clevis-locking pin is a one-time use only part. Anytime the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.
NOTE:Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.
2. Remove and discard the booster push rod clevis-locking pin.

3. Remove and discard the 4 brake booster nuts.

- To install, tighten to 23 Nm {2.3 kgf-m, 17 ft-lbf}.

4. Disconnect the vacuum hose/check valve assembly from the brake booster.

Hybrid vehicles

1. Disconnect the vacuum sensor, booster solenoid and booster travel sensor electrical connectors.

All vehicles

1. Remove and discard the 2 master cylinder nuts.

- To install, tighten to 30 Nm {3.0 kgf-m, 22 ft-lbf}.

NOTE:It is not necessary to disconnect the brake tube fittings.
2. Carefully position the brake master cylinder assembly forward and remove the brake booster.

CAUTION:Do not press, pull or otherwise move the brake pedal while installing the brake pedal position (BPP) switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.
3. To install, reverse the removal procedure.

Hybrid vehicles

1. Following the scan tool instructions, carry out the Multi-Calibration Routine.