Vacuum Brake Booster: Service and Repair

Brake Booster

Exploded View




















Removal

1. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5 times with the engine not running.

2. Remove the 4 strut upper mount nuts and remove the strut tower brace.

3. Remove the ACL (Air Cleaner) outlet pipe. REFER to Intake Air System Components - Exploded View .

4. Remove HCU (Hydraulic Control Unit). REFER to Hydraulic Control Unit (HCU) .

5. Remove the brake master cylinder. REFER to Brake Master Cylinder .

6. Disconnect the brake booster vacuum fitting and position aside.

7. 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. REFER to Stoplamp Switch .

8. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.

NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.
Remove and discard booster push rod clevis-locking pin.

9. Remove the 4 nuts and remove the brake booster.

- Discard the nuts.

Installation

1. Install the brake booster and the 4 new brake booster nuts.
- Tighten to 25 Nm (18 lb-ft)

2. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.
Install the new booster push rod clevis-locking pin.

3. 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.

Install the stoplamp switch. REFER to Stoplamp Switch .

4. Connect the brake booster vacuum fitting

5. Install the brake master cylinder. REFER to Brake Master Cylinder .

6. Install the HCU (Hydraulic Control Unit).

7. Install the ACL (Air Cleaner) outlet pipe.

8. Install the strut tower brace and the 4 strut upper mount nuts.
- Tighten to 30 Nm (22 lb-ft)