Removal and Installation

Removal
1. Disable airbag system as described under Technician Safety Information.
2. Remove master cylinder as outlined under MASTER CYLINDER.

Fig. 9 Brake Booster Removal:

3. On models with TRAC, proceed as follows:
a. Remove TRAC pump assembly, Fig. 9.
b. Remove brake tube between the TRAC accumulator and actuator from clamp No. 2.
4. Remove the No. 1 undercover and lower finish panel.
5. Remove pedal return spring, clip and clevis pin, clevis locknut and vacuum hose.
6. Remove brake booster nuts and pull out booster and gasket.

Installation
1. Adjust length of booster pushrod as follows:
a. Install gasket on master cylinder.
b. Install brake booster pushrod gauge tool No. 09737-00010, or equivalent on gasket.
c. Lower pin until its tip slightly touches the piston.
d. Turn gauge tool upside down and set it on booster.
e. Measure clearance between booster pushrod and pin head of gauge tool.
f. Adjust booster pushrod length until the pushrod slightly touches the pin head.
2. Install booster and gasket.
3. Install clevis to operating rod.
4. Install clevis pin into clevis and brake pedal then install clip to clevis pin.
5. On models with TRAC system, proceed as follows:
a. Install brake tube between the TRAC accumulator and actuator to clamp No. 2.
b. Install TRAC pump assembly.
6. Install lower finish panel, undercover and vacuum hose.
7. Install master cylinder, then fill and bleed brake system.
8. Bleed TRAC system as described under Traction Control Actuator.
9. Check and adjust pedal height and freeplay as described under ADJUSTMENT PROCEDURES.
10. Perform operational check as described under DIAGNOSIS AND TESTING PROCEDURES/TESTING PROCEDURES/BRAKE BOOSTER OPERATIONAL TEST.
11. Enable airbag system as described under Technician Safety Information.