Vacuum Brake Booster: Service and Repair

Master Cylinder Mounting:

Power Brake Booster Mounting:

Removing Vacuum Booster:

REMOVE
1. Remove both wiper arm assemblies.
2. Remove cowl panel cover to expose windshield wiper module.
3. Remove the 5 screws attaching the windshield wiper module to the dash panel. Remove the windshield wiper module from the vehicle.
4. Remove the 2 nuts attaching the master cylinder to the vacuum booster.
5. Carefully slide master cylinder off vacuum booster with brake lines attached, and place it against left shock tower.
6. Disconnect vacuum hose from power brake booster check valve. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER.
7. 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.
8. 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.
9. 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.
10. Slide the vacuum booster up and to the right (mounting holes are slotted) on the dash panel, then tilt outboard and up to remove from vehicle.

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


INSTALL
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 in. lbs.) torque.
3. Carefully position master cylinder on vacuum booster.
4. Install and tighten the 2 master cylinder to vacuum booster mounting nuts to 29 Nm (250 in. lbs.) torque.
5. Connect all vacuum hoses onto the vacuum booster check valve.
6. Using lubriplate, or equivalent, coat the bearing surface of pedal pin.
7. Connect vacuum booster input rod to brake pedal pin and install a NEW retainer clip. Use only a new retainer Clip DO NOT USE the old Clip.
8. Check stop light operation.
9. Install the windshield wiper module back into the dash panel opening. Install the 5 windshield wiper module attaching bolts and securely tighten.
10. Install cowl panel cover.
11. Install the windshield wiper arm assemblies back on pivots. Connect windshield washer hoses.