Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

1. Apply and release the brake pedal several times until it becomes firm to deplete the brake booster vacuum reserve.
2. Disconnect the vacuum power brake vacuum sensor electrical connector, if equipped.
3. Remove the vacuum power brake booster check valve and hose assembly from the brake booster grommet.
4. Remove the underhood electrical center and bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement (Removal and Replacement).
5. Remove the master cylinder. Refer to Master Cylinder Replacement (Automatic Transmission) (Master Cylinder Replacement (Automatic Transmission))Master Cylinder Replacement (Manual Transmission) (Master Cylinder Replacement (Manual Transmission)).




6. Remove the brake pedal pushrod nut (1).




7. Remove the brake pedal pushrod washer (1).
8. Remove the brake pedal pushrod from the brake pedal pivot pin.




9. Remove the vacuum brake booster nuts (1).




10. Remove the power brake vacuum booster (1).




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

Installation Procedure




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




2. Install the power brake vacuum booster (1).





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the vacuum brake booster nuts (1).

Tighten the nuts to 17 Nm (14 lb ft).




4. Apply a thin coating of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the pushrod pin on the brake pedal.
5. Connect the brake pedal pushrod to the brake pedal pivot pin.
6. Install the brake pedal pushrod washer (1).




7. Install the brake pedal pushrod nut (1).

Tighten the nut to 10 Nm (89 lb in).

8. Install the vacuum power brake booster check valve and hose assembly to the brake booster grommet.
If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve and hose assembly to the vacuum booster grommet. Do not use soap.
9. Connect the vacuum power brake vacuum sensor electrical connector, if equipped.
10. Install the master cylinder. Refer to Master Cylinder Replacement (Automatic Transmission) (Master Cylinder Replacement (Automatic Transmission))Master Cylinder Replacement (Manual Transmission) (Master Cylinder Replacement (Manual Transmission)).
11. Install the underhood electrical center and bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement (Removal and Replacement).