Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Special Tools

J 22805-B Brake Booster Holder


Removal Procedure

1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (Service and Repair) .
2. Without disconnecting the steering column from the intermediate shaft, lower the steering column assembly and support the column. Refer to Steering Column Replacement (Steering Column Replacement) .




3. Disconnect the brake pedal position sensor (1) electrical connector.




4. Remove the vacuum brake booster pushrod retaining clip (1).




5. Disconnect the vacuum brake booster pushrod (1) from the brake pedal pivot.




6. Remove the vacuum brake booster pushrod bushing (1).




7. Remove the vacuum brake booster pushrod wave washer (1).




8. Remove the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement) .
9. Disconnect the master cylinder fluid level sensor electrical connector.
10. Remove the master cylinder nuts (1).
11. Without disconnecting the brake pipes, position aside the master cylinder and support with heavy mechanics wire or equivalent.
12. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (Service and Repair) .
13. Without disconnecting the hoses, remove and position aside the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .




14. Disconnect the vacuum brake booster check valve and hose assembly (1) and position aside.




15. Install the J 22805-B (1) to the vacuum brake booster and secure with the master cylinder nuts.
16. Using a flat-bladed tool, depress the locking tab (2) toward the cowl.




17. Rotate the J 22805-B and vacuum brake booster (1) counter clockwise to release the vacuum brake booster from the bracket.

Important: Do not attempt to remove the vacuum brake booster completely. The vacuum brake booster pushrod retaining clip must be released prior to booster removal.


18. Carefully pull the vacuum booster forward slightly and support the vacuum booster to access the booster pushrod retaining clip.




19. Compress the vacuum brake booster foam filter to access the vacuum brake booster retaining clip.
20. Disconnect the brake booster pushrod (1) from the booster by releasing the retaining clip (2).
21. Remove the vacuum brake booster from the vehicle.
22. Remove the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if necessary.



Installation Procedure

Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.


Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.






1. Install the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if removed.
2. Position the vacuum brake booster to the vehicle.
3. Compress the vacuum brake booster foam filter to access the vacuum brake booster pushrod retaining clip.
4. Connect the brake booster pushrod (1) to the booster and engage the retaining clip (2).




5. Position the vacuum brake booster and the J 22805-B (1) to the bracket.
6. Rotate the vacuum booster clockwise until the locking tab (2) engages the cowl flange.
Ensure the booster locking tab fully engages in the bracket.
7. Remove the J 22805-B from the vacuum brake booster and discard the master cylinder nuts.




8. Install the vacuum brake booster check valve and hose assembly (1).




9. Install the master cylinder to the vacuum brake booster.

Notice: Refer to Fastener Notice (Fastener Notice) .

10. Install new master cylinder nuts (1).

Tighten the nuts to 25 N.m (18 lb ft).

11. Connect the master cylinder fluid level sensor electrical connector.
12. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (Service and Repair) .
13. Install the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .
14. Install the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement) .




15. Install the vacuum brake booster pushrod wave washer (1).




16. Install the vacuum brake booster pushrod bushing (1).




17. Connect the vacuum brake booster pushrod (1) to the brake pedal pivot.




18. Install the vacuum brake booster pushrod retaining clip (1).




19. Connect the brake pedal position sensor (1) electrical connector.
20. Install the steering column assembly. Refer to Steering Column Replacement (Steering Column Replacement) .
21. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration (Programming and Relearning) .
22. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (Service and Repair) .