Vacuum Brake Booster Replacement (Non-ABS)

REMOVAL PROCEDURE

NOTICE: Refer to Non Serviceable Booster Notice in Service Precautions.





1. Remove the master cylinder assembly.
2. Disconnect the brake vacuum hose (8) from the brake booster (1).
3. Remove the clevis pin (7) from the push rod clevis (6).
4. Disconnect the push rod clevis from the brake pedal arm.
5. Remove the nuts from the booster.
6. Remove the booster.

ADJUSTMENT PROCEDURE

^ Tools Required
- J 39567 Booster Piston Rod Height Gauge
- J 37767 Booster Push Rod Adjuster





1. Push the piston rod (2) several times, ensuring that the reaction disc is in place.
2. Maintain atmospheric pressure inside the booster when measuring the clearance.





3. Place the J 39567 on the master cylinder (1).
4. Push the J 39567 pin down until it touches the master cylinder piston (2).
5. Remove the J 39567 from the master cylinder.





6. Turn the J 39567 upside down and set it on the booster assembly (1).

Specification
The clearance (2) between the booster piston rod (3) and the J 39567 should be 0 mm (0 inch).





7. If the measurement does not equal the specification, use the J 37767 in order to hold the booster piston rod (1).
8. Turn the adjusting screw of the piston rod in order to adjust the clearance.

INSTALLATION PROCEDURE





1. Apply Wheel Bearing Lubricant, GM P/N 1051344, or the equivalent, to the master cylinder piston (3).





2. Install the booster to the bulkhead.

IMPORTANT: DO NOT tighten the nuts on the bulkhead before the clevis nut.

3. Install the 4 nuts (2).
4. Connect the booster push rod clevis (6) to the brake pedal [ever. Secure the clevis with the clevis pin and the clip.





5. Install the push rod clevis (3).

Measurement
The distance between the clevis pin hole and the brake booster assembly should be 109.5-110.5 mm (4.31-4.35 inch).

NOTICE: Refer to Fastener Notice in Service Precautions.

6. Tighten the clevis nut (2)
^ Tighten the clevis nut to 25 Nm (18.0 ft. lbs.).





7. Tighten the booster nuts (2).
^ Tighten the nuts to 13 Nm (115.0 inch lbs.).

8. Connect the brake vacuum hose to the brake booster. Secure the hose with the hose clamp.
9. Install the master cylinder.