Vacuum Brake Booster: Service and Repair

Brake Booster









Removal and Installation

NOTICE: Do not service the brake booster without first removing the stoplamp switch. Remove this switch with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) results in damage to the switch.

NOTICE: 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.

NOTICE: 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.

NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. Install this switch with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position results in incorrect adjustment and damages the switch.

1. Remove the battery tray.

2. Remove the upper intake manifold.

3. Disconnect the brake booster check valve from the brake booster.

4. Disconnect the vacuum hose and wire harness from the studs and remove the brake booster vacuum hose.

5. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
Remove and discard the 2 brake master cylinder nuts and position aside the brake master cylinder.

- To install, tighten the new nuts to 25 Nm (18 lb-ft).


6. Remove the stoplamp switch.

7. NOTE: The booster push rod clevis locking pin is a one-time use only part. Any time the pin is removed, a new one must be installed.

NOTE: An 11 mm, 12-point socket or wrench can be used to compress the 2 tabs on the locking pin.
Remove and discard the booster push rod locking pin.


8. Remove the 4 brake pedal booster nuts.
- To install, tighten to 23 Nm (17 lb-ft).


9. Remove the brake booster.

10. To install, reverse the removal procedure.