Vacuum Brake Booster: Service and Repair

REMOVAL






1. Remove the battery ground cable from the ground stud on the right strut tower. Then, correctly isolate the ground cable by installing the cable isolator on the ground stud.






2. Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nut. Remove the nut attaching each wiper arm to its pivot.
3. Remove the wiper arms from the pivots. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots.






4. Remove the wiper module cover and cowl cover from the vehicle.






5. Remove the 8 bolts, attaching the reinforcement to the strut towers and the 1 bolt attaching the wiper module to the reinforcement. Remove the reinforcement from the vehicle.
6. Disconnect the wire connector from the brake fluid level sensor on the right side of the master cylinder reservoir.






7. Remove the 2 nuts attaching the master cylinder to the vacuum booster.






8. Carefully slide master cylinder off vacuum booster with brake lines attached, and position it backwards, on top of left engine cylinder head cover.
9. Disconnect vacuum hose from power brake booster check valve. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER.
10. From under instrument panel, position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip.
11. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull retainer clip off pin. Discard retainer clip it is not to be reused, replace only with a new retainer clip.
12. Remove the four nuts that attach the vacuum booster to the vehicle dash panel. Nuts are accessible from under the dash panel in the area of the steering column and pedal bracket.






13. Rotate the windshield wiper motor crank lever until the crank lever points in the 12 o'clock position.
14. Slide the vacuum booster out of the dash panel, and remove from vehicle.

CAUTION: Do not attempt to disassemble the vacuum booster. It is serviced ONLY as a complete assembly.

INSTALLATION
1. Position vacuum booster on dash panel.
2. Install and tighten the 4 power brake booster to dash panel mounting nuts to 29 Nm (250 inch lbs.) torque.
3. Using lubriplate, or equivalent, coat the bearing surface of brake pedal pin.
4. Connect vacuum booster input rod to brake pedal pin and install a NEW retainer clip. Use only a new retainer clip.

NOTE: Before installing master cylinder, reposition under hood wiring harness above master cylinder mounting studs, in front of booster.

5. Carefully position master cylinder on vacuum booster. Position wire harness routing bracket onto right master cylinder mounting stud.
6. Install and tighten the 2 master cylinder to vacuum booster mounting nutsto 29 Nm (250 inch lbs.) torque.
7. Reconnect brake fluid level sensor connector.
8. Connect all vacuum hoses onto the vacuum booster check valve.
9. Check stop light switch operation.
10. Install the wiper module reinforcement on the vehicle. Install the 8 bolts, attaching the reinforcement to the strut towers. Install the bolt attaching the wiper module to the reinforcement.
11. Install the covers over the wiper module and the cowl. Install and securely tighten the attaching screws.
12. Reconnect the battery ground cable to the ground stud on the shock tower.
13. Turn windshield wipers on, then off, in order to park wipers in the proper position before installing wiper arms.
14. Install the wiper arms on the pivots. Install and securely tighten the wiper arm to pivot attaching nuts. Install the caps on the wiper arms covering the pivot nuts.
15. Verify proper operation of the brake booster and brake system.