Vacuum Brake Booster: Service and Repair

NOTE: To simplify the removal process, it is suggested that the battery and battery mounting tray be removed first.

REMOVAL
1. Disconnect the brake fluid level switch connector.
2. Disconnect the four brake lines with a flare nut wrench.
3. Remove the two nuts holding the master cylinder onto the power brake unit and remove the master cylinder.
4. Disconnect the vacuum hose.
5. From inside the vehicle, remove the spring clip and clevis pin, disconnecting the master cylinder pushrod.
6. Remove the four nuts that hold the power brake unit to the bulkhead and remove the unit.

INSTALLATION
1. Mount the power brake unit on the vehicle bulkhead (with a new gasket) and, from inside the vehicle, install the four mounting nuts. Tighten the mounting nuts to 15-24 ft. lbs. (20-32 Nm).
2. Attach the pushrod clevis to the brake pedal with a new clevis pin and new spring clip.
3. From the engine compartment, attach the vacuum hose to the check valve.
4. Mount the master cylinder onto the power brake unit and install two nuts.
- Tighten the master cylinder mounting nuts to 9-15 ft. lbs. (12-20 Nm).
5. Connect the four brake lines. Tighten brake line flare nuts.
- Tightening torque: 9-15 ft. lbs. (12-20 Nm).
6. Connect the brake fluid level switch.
7. Mount the battery tray.
8. Install the battery.
9. Mount bakery hold-down strap and fasten with two bolts.
- Tightening torque: 9-15 ft. lbs. (12-20 Nm).
10. Fill the reservoir to the MAX level line with new fluid.
- Brake fluid: SAE J1703 DOT-3 or DOT-4.
11. Bleed the system. Service and Repair
12. Inspect the system for leaks.
13. Check the brake pedal height and free play and adjust as necessary. Adjustments