Power Vacuum Brake Booster Replacement (J65)

Power Vacuum Brake Booster Replacement (J65)

Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Vehicle Damage Warnings).




1. Turn the ignition switch to the OFF position.
2. Release the brake pipe retainers (1) from the front LH frame rail.
3. Remove the brake master cylinder. Refer to Master Cylinder Replacement (JL9) (Master Cylinder Replacement (JL9))Master Cylinder Replacement (J65) (Master Cylinder Replacement (J65)).




4. Disconnect the vacuum brake booster check valve and hose assembly (1) from the vacuum brake booster and position aside.




5. Remove the proportioning valve bracket bolts (1).
6. Carefully position proportioning valve and bracket assembly forward.




7. Remove the power brake booster pushrod nut (1).




8. Remove the vacuum brake booster nuts (1).
9. Disconnect the vacuum brake booster pushrod from the brake pedal pivot pin.




10. Pull the vacuum brake booster (1) forward until the studs clear the dash panel.
11. Maneuver the vacuum brake booster upward until the booster pushrod clears the dash panel and remove the brake booster.




12. Remove the vacuum brake booster front of dash seal (1).
Inspect the seal for damage and replace if necessary.




13. Remove the vacuum brake booster gasket (1).
Inspect the gasket for damage and replace if necessary.

Installation Procedure




1. Install the vacuum brake booster gasket (1).




2. Install the vacuum brake booster front of dash seal (1).




3. Install the vacuum brake booster (1) to the dash panel.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the vacuum brake booster nuts (1) and tighten to 25 Nm (18 lb ft).
5. Apply a thin coat of high-temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the brake pedal pivot bushing, the pushrod washer, the push rod pin on the pedal, and the brake pedal pivot pin.
6. Connect the vacuum brake booster pushrod from the brake pedal pivot pin.
7. Install the vacuum brake booster pushrod spacer (1).




8. Install the power brake booster pushrod nut (1) and tighten to 10 Nm (89 lb in).




9. Carefully position proportioning valve and bracket assembly rearward.
10. Install the proportioning valve bracket bolts (1) and tighten to 10 Nm (89 lb in).




11. Connect the vacuum brake booster check valve and hose assembly (1) to the vacuum brake booster.
If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve to the booster grommet. Do not use soap.




12. Install the brake master cylinder. Refer to Master Cylinder Replacement (JL9) (Master Cylinder Replacement (JL9))Master Cylinder Replacement (J65) (Master Cylinder Replacement (J65)).
13. Install the brake pipe retainers (1) to the front LH frame rail.
14. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration (Programming and Relearning).