Braking Sensor/Switch: Service and Repair

When removing pedal travel sensor, brake booster must be bled of vacuum. If not pedal travel sensor sealing O-ring may be sucked into the brake booster. If O-ring falls into booster, booster must be replaced.

1. Pump brake pedal 20 times to evacuate all stored vacuum from brake booster, then remove electrical connector from pedal travel sensor.

Fig 69 Pedal Travel Sensor Retaining Ring Removal:

2. Using a small screwdriver remove pedal travel sensor retaining ring.
3. Pull pedal travel sensor straight out from booster, then remove pedal travel O-ring.
4. Reverse procedure to install noting the following:
a. Tab of retaining ring should be located in top notch of mounting grommet.
b. Lubricate O-ring with brake fluid before installing.
c. Ensure travel sensor is inserted into grommet until tab on travel sensor is past retaining ring.