Vacuum Brake Booster: Service and Repair
Power Vacuum Brake Booster Replacement
Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).
1. Apply the park brake.
2. Deplete the vacuum reserve in the vacuum booster by applying the brake pedal 3 times or until the brake pedal becomes firm.
3. Remove the electrical connectors for the DOD sensor (1) and the active booster connector (2).
4. Remove the vacuum hose from the check valve (3).
5. Remove the 2 master cylinder nuts.
Note:
* It is not necessary to disconnect the brake pipes from the master cylinder.
* Ensure the O-ring vacuum seal is on the master cylinder after removal.
6. Position the master cylinder aside and secure with heavy mechanics wire or equivalent.
7. Remove the brake booster pushrod retainer bolt (1).
8. Remove the brake booster pushrod retainer (1).
9. Remove the stoplamp switch (1).
10. Disconnect the brake booster pushrod from the brake pedal pivot pin.
11. Remove the brake booster nuts (1).
12. Remove the power vacuum brake booster.
13. Remove and discard the brake booster gasket.
Installation Procedure
1. Install a new brake booster gasket.
Note: An assistant may be necessary to hold the brake booster in place while installing the nuts.
2. Install the power vacuum brake booster to the vehicle.
Caution: Refer to Fastener Caution (Fastener Caution).
Note: Tighten the upper right brake booster nut first.
3. Install the brake booster nuts (1) and tighten to 33 Nm(24 lb ft).
4. Connect the brake booster pushrod to the brake pedal pivot pin.
5. Install the stoplamp switch (1).
6. Install the brake booster pushrod retainer (1).
7. Install the brake booster pushrod retainer bolt (1) and tighten to 10 Nm(89 lb in).
8. Install the vacuum hose to the check valve (3).
9. Connect the electrical connectors to the DOD sensor (1) and the active booster connector (2).
10. Install the master cylinder.
11. Install the 2 master cylinder nuts and tighten to 33 Nm(24 lb ft).