Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

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 Brake Fluid Effects on Paint and Electrical Components Caution.

1. Remove the vacuum brake booster vacuum sensor and hose from the vacuum brake booster and position aside. Refer to Power Brake Booster Vacuum Sensor Replacement (3.0L) Power Brake Booster Vacuum Sensor Replacement (3.0L)Power Brake Booster Vacuum Sensor Replacement (2.4L) Power Brake Booster Vacuum Sensor Replacement (2.4L).

2. Remove the master cylinder. Refer to Master Cylinder Replacement Removal and Replacement.

3. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement.

4. Remove the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement.





5. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .

6. Remove the vacuum brake booster pushrod retainer nut (1).

7. Disconnect the vacuum brake booster pushrod from the brake pedal.





8. Remove the 4 vacuum brake booster nuts (1).





9. Carefully pull the vacuum brake booster forward until the mounting studs clear the dash panel.

Note:
Ensure the foam insulator on the mounting surface of the vacuum brake booster withdraws with the booster.

10. Remove the vacuum brake booster (1).





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

Installation Procedure





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





Note:
Ensure the foam insulator on the mounting surface of the vacuum brake booster is properly installed on the booster.

2. While guiding the brake booster pushrod and mounting studs through the dash panel, install the vacuum brake booster (1).





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the vacuum brake booster nuts (1) and tighten to 25 Nm (18 lb ft)..





4. Connect the vacuum brake booster pushrod to the brake pedal.

5. Install the vacuum brake booster pushrod retainer.

6. Rotate the vacuum brake booster pushrod retainer 360 degrees to ensure it is properly installed.

7. Install the vacuum brake booster pushrod retainer nut (1) and tighten to 25 Nm (18 lb ft)..

8. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .

9. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement.

10. Install the BPMV. Refer to Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement.

11. Install the master cylinder. Refer to Master Cylinder Replacement Removal and Replacement.





12. Install the vacuum brake booster vacuum sensor (1) and hose to the vacuum brake booster. Refer to Power Brake Booster Vacuum Sensor Replacement (3.0L) Power Brake Booster Vacuum Sensor Replacement (3.0L)Power Brake Booster Vacuum Sensor Replacement (2.4L) Power Brake Booster Vacuum Sensor Replacement (2.4L).