Vacuum Brake Booster: Service and Repair
Removal1. Remove master cylinder assembly from booster.
2. Disconnect vacuum hose.
3. Remove push rod clevis pin and booster mounting nuts and then remove booster.
Installation
NOTE:
^ Adjust clearance between booster piston rod and master cylinder piston.
^ Check length of push rod clevis.
1. Install booster (4) to dash panel. Then connect push rod clevis (5) to pedal arm with clevis pin (2) and clip (1).
2. Tighten booster mounting nuts (3) to specified torque.
Tightening torque
Booster mounting nuts (a): 13 Nm (1.3 kgf-m, 9.5 ft. lbs.)
3. Install brake vacuum hose to booster.
4. Install master cylinder assembly to booster.
5. Fill reservoir with specified fluid.
6. Bleed air from brake system.
7. Perform brake test and check each installed part for fluid leakage.
Brake Booster Inspection and Adjustment
Installation Position of Push Rod
If push rod clevis (1) has been removed, adjust distance between booster installation surface (without including packing) and the center of clevis pin hole to standard value "a" and tighten nut (2) to specified torque.
Distance "a" between center of booster clevis pin hole and booster surface
Standard: 104.5 - 105.5 mm (4.11 - 4.15 inch)
Tightening torque
Clevis pin lock nut (a): 25 Nm (2.5 kgf-m, 18.5 ft. lbs.)
Clearance Between Booster Piston Rod and Master Cylinder Piston
1. Set special tool (A) on master cylinder (1) and push pin head (3) until it contacts piston (2).
Special tool: (A): 09950-96010
2. Turn special tool upside down and place it on booster (1). Adjust booster piston rod (2) length until rod end contacts pin head.
Clearance "b" (Between special tool and piston rod)
0 mm (0 inch)
Special tool: (A): 09950-96010
3. Adjust clearance by turning adjusting screw of piston rod.
Special tool: (B): 09952-16010