Vacuum Brake Booster: Service and Repair

VACUUM BOOSTER

REMOVAL

1. On vehicles equipped with ABS, the ABS Controller must be removed.





2. Remove brake pipes from master cylinder.
3. Disconnect low brake fluid switch electrical connector.





4. Remove master cylinder-to-brake booster nuts.
5. Remove master cylinder from vehicle.





6. Disconnect vacuum check valve and hose from booster.





7. Remove left lower I/P closeout panel (hush panel).





8. Remove booster push rod retainer and push rod from brake pedal.





9. Remove brake booster-to-brake booster bracket attachment bolts.

IMPORTANT: The top bolt is accessed through the inside of the HVAC filter plenum.

9.1 Open the HVAC filter access panel.
9.2 Remove rubber plug in bottom of cowling.
9.3 Remove top brake booster-to-brake booster bracket bolt.





10. From under hood, remove booster.

INSTALLATION





1. Position booster in vehicle. Install brake booster-to-brake booster bracket attachment bolts.
Torque: Brake Booster-to-Brake Booster Bracket Bolts: 20 Nm (15 ft. lbs.)
2. Install rubber plug in bottom of cowling.
3. Close and secure HVAC access panel.





4. Install booster push rod onto brake pedal pushrod pin with retainer.





5. Install lower left I/P closeout panel (hush panel).





6. Connect vacuum hose and check valve to booster.





7. Position master cylinder onto brake booster and install fastening nuts.
Torque: Master Cylinder-to-Brake Booster Nuts: 25 Nm (18 ft. lbs.)

NOTICE: Do not bend brake pipes.





8. Position brake pipes into master cylinder and tighten nuts.
Torque: Brake Pipes-to-Master Cylinder: 18 Nm (13 ft. lbs.)
9. Connect low brake fluid electrical connector.
10. On vehicles equipped with ABS, install ABS Controller.
11. Bleed brakes.