Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE MASTER CYLINDER
2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
Using pliers, slide the clip and disconnect the vacuum hose from the brake booster and remove the clip.
3. DISCONNECT 3 BRAKE LINES FROM CLAMP
4. REMOVE RETURN SPRING
5. REMOVE CLIP AND CLEVIS PIN





6. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.

INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD





(a) Set 2 feeler gauges (0.3 mm) to the cylinder body symmetrically.
(b) Set the SST on the 2 feeler gauges, and lower the pin until its tip slightly touches the piston.
SST 09737-00012





(c) Turn the SST upside down, and set it on the booster.
SST 09737-00012
(d) Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 in.)

HINT: When adjusting the push rod, depress the brake pedal enough so that the push rod sticks out.





(e) Using SST adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020

3. INSTALL MASTER CYLINDER
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. CONNECT BRAKE LINES TO BRACKET
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
7. CHECK FOR FLUID LEAKAGE
8. CHECK AND ADJUST BRAKE PEDAL
9. DO OPERATIONAL CHECK