Vacuum Brake Booster: Service and Repair

Removal
1. Remove brake master cylinder.
2. Disconnect master vacuum hose from master vacuum.
3. From inside vehicle, remove spring clip from clevis pin and clevis pin.
4. Remove four master vacuum nuts. Secure master vacuum to bulkhead.
5. Remove master vacuum.
6. Remove master vacuum mounting bracket gasket.

Replacement
1. Mount master vacuum on vehicle bulkhead (with a new gasket) from inside the vehicle and install four mounting nuts. Tighten mounting nuts.
Tightening torque: 14 - 19 ft. lbs. (19 - 26 Nm, 1.9 - 2.6 kg-m)
2. Attach pushrod clevis pin to the brake pedal with a new clevis pin and new spring clip.
3. From engine compartment, attach vacuum hose to the check valve.
4. Mount master cylinder onto power brake unit and install two nuts. Tighten master cylinder mounting nuts.
Tightening torque: 7 - 12 ft. lbs. (9.8 - 16 Nm, 1.0 - 1.6 kg-m)
5. Connect four brake lines. Tighten brake line flare nuts.
Tightening torque: 9 - 16 ft. lbs. (13 - 22 Nm, 1.3 - 2.2 kg-m)
6. Connect brake fluid level switch.
7. Fill reservoir with new fluid to Max level line. (Brake fluid SAE J1703 DOT-3 or DOT-4.)
8. Bleed system. Refer to Brake Bleeding; Service and Repair.
9. Inspect system for leaks.
10. Check brake pedal height and free play and adjust as necessary.