Hydraulic Brake Booster: Service and Repair

Hydraulic Brake Booster Replacement

Caution: Refer to Brake Fluid Irritant in Service Precautions.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components in Service Precautions.

Notice: 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.

Checking and Adding Fluid
For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid (Without Hydroboost) or Checking and Adding Power Steering Fluid (With Hydroboost) in Power Steering System.

Bleeding the Hydraulic Booster System
Refer to Bleeding the Power Steering System in Power Steering System

Flushing the Hydraulic Booster System
Refer to Flushing the Power Steering System in Power Steering System.

Removal Procedure
1. Apply the park brake and block the wheels.
2. Disconnect the inlet hose, the steering gear. and the return hoses from the booster assembly
3. Remove the master cylinder. Refer to Master Cylinder Replacement.
4. Remove the stop lamp switch Refer to Stop Lamp Switch Replacement in Lighting Systems.





5. Remove the 4 booster to bulkhead nuts.
6. Remove the booster assembly.
7. Remove the gasket.

Installation Procedure
1. Install the gasket.





2. Install the booster assembly.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the 4 booster to bulkhead nuts.
Tighten the nuts to 33 Nm (24 ft. lbs.).
4. Install the stop lamp switch. Refer to Stop Lamp Switch Replacement in Lighting Systems.
5. Install the master cylinder. Refer to Master Cylinder Replacement
6. Connect the return hose, the steering gear, and the inlet hoses.
7. Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System.
8. Release the park brake and unblock the wheels.