Vacuum Brake Booster: Service and Repair

Brake Booster - Vacuum









Removal and Installation

1. Remove the brake master cylinder. For additional information, refer to Hydraulic Brake Actuation Brake Master Cylinder.

2. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp 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.

Remove the stoplamp switch. For additional information, refer to Exterior Lighting Service and Repair.

3. Disconnect the brake booster check valve.

4. Disconnect the brake booster push rod in the following sequence.

1. Remove the brake booster push rod cotter pin cover.

2. Remove the brake booster push rod cotter pin.

3. Remove the spacer.

4. Disconnect the brake booster push rod from the brake pedal pin.

5. Remove the 4 brake booster nuts and the brake booster.
- To install, tighten to 25 Nm (18 lb-ft).

6. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch.

To install, reverse the removal procedure.

- Apply brakes several times to verify correct brake operation.