Vacuum Brake Booster Replacement

Removal Procedure





1. Remove the brake modulator assembly (if equipped with ABS). Refer to Brake Modulator Assembly Replacement.
2. Remove the master cylinder. Refer to Master Cylinder Replacement.
3. Remove the hose clamp and the hose from the booster (1).





4. Remove the cotter pin (1) and the clevis pin (6) from the push rod clevis (5).
5. Remove the push rod clevis (5) from the brake pedal.
6. Remove the four mounting nuts (2) and the booster assembly from the bulkhead.

Adjustment Procedure

- Tools Required
- J 39567 Brake Booster Piston Rod Height Gauge





1. Adjust the booster piston rod to the master cylinder piston (3). Push the booster piston rod (2) several times in order to ensure that the reaction disc is in place.





2. Set the J 39567 on the master cylinder (1).
3. Push the J39567pin down until the pin touches the master cylinder piston (2).
4. Remove the J 39567 from the master cylinder (1).





5. Turn the J 39567 upside down and set it on the booster assembly (1).
6. Measure the clearance (2) between the booster piston rod and the J 39567 Ensure that there is no clearance (0 mm, 0 inch) between the booster piston rod (3) and the J 39567.
7. If the booster piston rod length is not within specifications, adjust the length by turning the booster piston rod adjusting nut until the specification is reached.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. Measure the push rod clevis length. Install the push rod clevis (2) so that a push rod clevis length ranging from 99.5 - 100.5 mm (3.92 - 3.96 inch) is obtained.
- Tighten the push rod clevis locknut to 25 Nm (18 ft. lbs.).
2. Apply silicone grease to the master cylinder piston.
3. Install the booster assembly to the bulkhead. Do not tighten the mounting nuts.





4. Install the push rod clevis (5) to the brake pedal. Secure the push rod clevis with a clevis pin (6) and cotter pin (1).
5. Secure the booster assembly mounting nuts.
- Tighten the booster assembly mounting nuts to 13 Nm (115 inch lbs.).
6. Install the hose to the booster assembly. Secure the hose with a hose clamp.
7. Install the master cylinder. Refer to Master Cylinder Replacement.
8. Install the brake modulator assembly (if equipped with ABS). Refer to Brake Modulator Assembly Replacement.