Vacuum Brake Booster: Service and Repair

REMOVAL
1. Remove or disconnect the following parts at engine compartment.
1 Disconnect the connector for brake fluid level gauge.
2 Remove the brake pipes from master cylinder.
3 Remove the master cylinder installing nuts.
4 Disconnect the vacuum hose from brake booster.
2. Remove the following parts from pedal bracket.
1 Snap pin and clevis pin





2 Four brake booster installing nuts
3. Remove the brake booster while shunning brake pipes.

NOTE:
^ Do not apply strong impact to booster shell and vacuum pipe.
^ Be careful not to drop the brake booster. The brake booster should be replaced if it has been dropped.
^ Use special care when handling the operating rod. If excessive force is applied to operating rod sufficient to cause a change in the angle in excess of ±3°, it may result in damage to the power piston cylinder.
^ Use care when placing the brake booster on the floor.
^ Do not change the push rod length.





CAUTION:
^ Do not disassemble the brake booster.
^ If external force is applied from above when brake booster is placed in this position, the resin portion as indicated by "P", may be damaged.

INSTALLATION
1. Check and adjust the operating rod of brake booster.
Standard L: 136.3 mm (5.38 inch)





If it is not within the specified value, adjust it by adjusting the brake booster operating rod.
2. Mount the brake booster in position.





3. Connect the operating rod to brake pedal with clevis pin and snap pin.

NOTE: Apply a thin coat of grease [SUNLIGHT 2 (Part No. 003602010)] to clevis pin.

4. Connect the vacuum hose to brake booster.





5. After replacing the O-ring with a new one, install the master cylinder to brake booster.
6. Connect the brake pipes to master cylinder.
7. Connect the connector for brake fluid level gauge.





8. Measure the clearance between the threaded end of stop light switch and stopper.
If it is not within specified value, adjust it by adjusting the position of stop light switch.

CAUTION: Be careful not to rotate the stop light switch.

9. Apply grease to the operating rod connecting pin to prevent it from wearing.
10. Bleed air from the brake system.
Tightening torque (Air bleeder screw): 8 Nm (0.8 kgf-m, 5.8 ft. lbs.)
11. Conduct road tests to ensure brakes do not drag.