Vacuum Brake Booster: Service and Repair

Brake Booster

Brake Booster:

Removal and Installation
1. Remove the brake master cylinder.
2. Disconnect the brake booster vacuum fitting and position aside.

3. CAUTION: Do not service the brake pedal or brake booster without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch.





4. CAUTION: Do not service the brake pedal or brake booster without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

If equipped, remove the speed control deactivation switch.





5. Remove the redundant self-locking pin cover and the self-locking pin.
^ Remove the booster rod and washer from the brake pedal.
6. Remove and discard the 4 nuts and remove the brake booster.
^ To install, tighten to 25 Nm (18 lb-ft).

7. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.

To install, reverse the removal procedure.