Power Brake Booster Replacement (Without JF4)

Power Brake Booster Replacement (Without JF4)

Removal Procedure

Caution: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid.

1. Apply the parking brake.
2. With the engine OFF, apply and release the brake pedal several times until the pedal becomes firm to deplete the power brake booster reserve.
3. Without disconnecting the brake pipes, remove and position aside the brake master cylinder and secure with heavy mechanics wire or equivalent. Refer to Master Cylinder Replacement (Two-Mode Hybrid) (Removal and Replacement)Master Cylinder Replacement (Vacuum Assist) (Removal and Replacement)Master Cylinder Replacement (Hydraulic Assist) (Removal and Replacement).




4. Release the clamp and disconnect the power brake booster fluid return hose (1).




5. Disconnect the power brake booster fluid inlet pipe fitting (1).




6. Disconnect the power brake booster fluid outlet pipe fitting (1).




7. Disconnect the stop lamp switch electrical connector.
8. Remove the brake booster pushrod retainer bolt (1).




9. Remove the brake booster pushrod retainer (1).
10. Disconnect the power brake booster pushrod from the brake pedal pin while simultaneously removing the stop lamp switch.




11. Remove the 4 power brake booster nuts (1).
12. Remove the power brake booster.

Installation Procedure




1. Install the power brake booster.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Tighten the upper right hand nut first.

2. Install the 4 power brake booster nuts (1) and tighten to 33 Nm (24 lb ft).




3. Simultaneously install the stop lamp switch with the power brake booster pushrod to the brake pedal pin.
4. Install the brake booster pushrod retainer (1).




5. Install the brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in).
6. Connect the stop lamp switch electrical connector.




7. Install the power brake booster hose outlet pipe fitting (1) and tighten to 33 Nm (24 lb ft).




8. Install the power brake booster hose inlet pipe fitting (1) and tighten to 33 Nm (24 lb ft).




9. Install the power brake booster fluid return hose (1) and secure the clamp.
10. Install the brake master cylinder. Refer to Master Cylinder Replacement (Two-Mode Hybrid) (Removal and Replacement)Master Cylinder Replacement (Vacuum Assist) (Removal and Replacement)Master Cylinder Replacement (Hydraulic Assist) (Removal and Replacement).
11. Bleed the power steering system. Refer to Power Steering System Bleeding (Service and Repair).