Vacuum Brake Booster: Service and Repair

Brake Booster

Brake Booster:

Removal and Installation

1. CAUTION: Do not service the brake pedal or brake booster without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch.

2. CAUTION: The brake booster check valve must be disconnected from the brake booster (prior to removing the master cylinder) or the master cylinder seal may be drawn into the brake booster.

Disconnect the brake booster check valve from the brake booster to deplete the residual vacuum in the brake booster.
3. Remove the brake master cylinder.

4. CAUTION: Make sure that the vacuum hose assembly is routed correctly so it does not make contact with surrounding components or damage to the hose may occur.

Disconnect the vacuum hose and wire harness from the studs and position aside.





5. Remove the brake booster push rod pin and clip and disconnect the push rod from the brake pedal.
6. Remove the 4 brake booster nuts.
^ To install, tighten to 23 Nm (17 lb-ft).
7. Remove the brake booster.

8. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.

To install, reverse the removal procedure.
9. Check the brake booster for correct operation.