Vacuum Brake Booster Replacement
Removal Procedure1. Remove the windshield wiper transmission. Refer to Wiper Transmission Replacement in Wiper and Washer Systems.
2. Remove the A/C evaporator tube extension from the cowl. Refer to Evaporator Tube Extension Replacement in Heating and Air Conditioning with AC Automatic.
3. Disconnect the brake fluid level sensor connection (1) from the reservoir cap.
4. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
5. Remove the power brake booster vacuum hose (1) from the power brake booster.
6. Remove the driver side front floor air outlet duct.
7. Remove the brake pedal pivot pin retainer (1) from the brake pedal pivot pin (2).
8. Press the brake pedal pivot pin (2) out of the brake master cylinder pushrod clevis.
Important: Ensure not to disturb the clevis adjustment on the pushrod unless replacing the power brake booster.
9. Remove the brake master cylinder pushrod clevis from the brake pedal.
10. Remove the fuse and relay panel screws.
11. Remove the fuse and relay panel. Position the fuse and relay panel out of the way.
12. Remove the brake pedal bracket nuts (1).
13. Remove the power brake booster with gasket (to cowl) from the cowl.
14. Remove the power brake booster support bracket nuts.
15. Remove the power brake booster support bracket washers.
16. Remove the power brake booster support bracket and gasket from the booster.
17. Remove the clevis and the power brake booster pushrod nut if replacing the power brake booster.
Installation Procedure
1. Install the clevis and install the adjusting nut to the new booster if replacing the power brake booster.
2. Adjust the clevis on the pushrod to dimension (1) 105.5 - 106.5 mm (4.0 - 4.4 inches).
3. Tighten the adjusting nut.
4. Use dimension (2) 179 - 181 mm (6.7 - 0.4 inches) for an additional check.
5. Install the power brake booster gasket to the booster.
6. Install the support bracket to the booster.
7. Install the support bracket washers to the booster.
Notice: Refer to Fastener Notice in Service Precautions.
8. Install the support bracket nuts to the booster.
^ Tighten the support bracket nut to 18 Nm (13 ft. lbs.).
9. Position the power brake booster gasket (to cowl) over the studs on the bracket; if removed.
Important: Ensure the mounting surface if free of sealant or any other foreign material.
10. Install the booster to the cowl.
11. Install the brake pedal bracket nuts (1).
^ Tighten the brake pedal bracket nuts (1) to 20 Nm (15 ft. lbs.).
12. Position the fuse and relay panel.
13. Install the fuse and relay panel screws.
^ Tighten the fuse and relay panel screws until fully seated. Ensure not to strip the fuse and relay panel screws.
14. Install the brake master cylinder pushrod clevis to the brake pedal.
15. Install the brake pedal pivot pin (2) and install the brake pedal pivot pin retainer (1).
16. Install the driver side front floor air outlet duct.
17. Install the power brake booster vacuum hose (1) to the power brake booster.
18. Install the brake master cylinder. Refer to Master Cylinder Replacement.
19. Connect the brake fluid level sensor connection (1) to the reservoir cap.
20. Install the A/C evaporator tube extension to the cowl. Refer to Evaporator Tube Extension Replacement in Heating and Air Conditioning with AC Automatic.
21. Install the windshield wiper transmission. Refer to Wiper Transmission Replacement in Wiper and Washer Systems.
22. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.