Vacuum Brake Booster: Service and Repair
Power Vacuum Brake Booster Replacement
Removal Procedure
1. Place the ignition switch in the OFF position.
2. Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
3. Disconnect the electrical connector and remove the power brake booster vacuum sensor (1) and vacuum hose and position aside.
4. Remove the brake master cylinder nuts (1).
5. Without disconnecting the brake pipe fittings from the master cylinder, remove the brake master cylinder and support with heavy mechanics wire or equivalent.
6. Inspect the O-ring seal on the master cylinder body for damage and replace, if necessary.
7. Remove the brake booster pushrod retainer bolt (1).
8. Remove the brake booster pushrod retainer (1).
9. Disconnect the electrical connector and remove the stoplamp switch (1).
10. Disconnect the brake booster pushrod from the brake pedal pin.
11. Remove the power vacuum brake booster nuts (1).
12. Remove the power vacuum brake booster.
13. Remove and discard the power vacuum brake booster gasket.
Installation Procedure
1. Install a new power vacuum brake booster gasket.
2. Install the power vacuum brake booster.
Caution: Refer to Fastener Caution Fastener Caution.
3. Install the power vacuum brake booster nuts (1) and tighten to 33 Nm (24 lb ft).
4. Connect the brake booster pushrod to the brake pedal pin.
5. Install the stoplamp switch (1).
6. Connect the stoplamp switch electrical connector.
7. Install the brake booster pushrod retainer (1).
8. Install the brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in).
9. Install the O-ring seal on the master cylinder body, if removed.
10. Position the master cylinder to the power vacuum brake booster.
11. Install the brake master cylinder nuts (1) and tighten to 33 Nm (24 lb ft).
Note: A small amount of denatured alcohol may be used to ease assembly, if necessary.
12. Install the power brake booster vacuum sensor (1) and vacuum hose.
13. Connect the power brake booster vacuum sensor electrical connector.