Vacuum Brake Booster: Service and Repair

REMOVAL
1. Remove following parts:
a. Master cylinder.
b. Vacuum hose, clip and return spring.





2. Remove brake booster.
a. Remove the 4 booster installation nuts and clevis.
b. Remove the booster and gasket.

INSTALLATION
1. Install brake booster.
a. Install the clevis to the operating rod.
b. Install the booster and new gasket.
c. Install and torque the booster installation nuts.
Torque: 12 Nm (9 ft. lbs.)
d. Insert 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. Install the gasket on the master cylinder.
b. Set the Special Service Tool (SST) 09737-00010 or equivalent, on the gasket, and lower the pin until its tip slightly touches the piston.
c. Turn the SST 09737-00010 upside down, and set it on the booster.
d. Measure the clearance between the booster push rod and pin head.





e. Adjust the booster push rod length until the push rod slightly touches the pin head.

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

3. Install these parts:
a. Vacuum hose.
b. Master cylinder.
4. Fill brake reservoir with brake fluid and bleed brake system.
5. Check for fluid leakage.
6. Check and adjust brake pedal.
7. Do operational check.