Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure




1. Disconnect and remove the battery.
2. Remove and position aside the underhood electrical center.
3. Remove the battery tray.
4. Disconnect the coolant surge hose from the surge tank and position aside.
5. Remove the master cylinder mounting nuts. Do NOT disconnect the brake pipes from the master cylinder.
6. Carefully pull the master cylinder away from the vacuum booster and position aside.
7. Disconnect the vacuum booster check valve and hose assembly from the booster.




8. Remove the transaxle control module (TCM) and position over engine.
9. Remove the brake modulator assembly, if equipped.




10. Remove the brake modulator valve bracket, if equipped.




11. Remove the brake booster push rod-to-brake pedal retaining clip.
12. Remove the foam washer from the brake pedal assembly.




13. Remove the brake booster mounting nuts.

Important: Ensure that the foam insulator on the mounting surface of the brake booster withdraws with the booster.

14. Disengage the brake booster from the front of dash and the brake pedal bracket. Maneuver the booster toward the center of the vehicle in order to ease removal.

Installation Procedure




1. Install the foam insulator the vacuum brake booster.
2. Install the brake booster to the vehicle.
3. Install, but do not tighten, the booster mounting nuts.
4. Lightly lubricate the booster push rod pivot pin on the brake pedal with silicone lubricant.
5. Install the booster push rod to the pivot pin on the brake pedal.
6. Install the foam washer to the pivot pin.
7. Install the brake booster push rod retaining clip.




8. Fully seat the brake booster to the front of dash and the brake pedal assembly.

Notice: Refer to Fastener Notice.

9. Tighten the vacuum brake booster mounting nuts.

Tighten the nuts to 25 N.m (18 lb ft).




10. Install the brake modulator valve bracket, if equipped.
11. Install the brake modulator assembly, if equipped.




12. Install the TCM to the bracket.




13. Install the vacuum booster check valve and hose assembly to the booster.
14. Reposition and install the master cylinder to the booster.




15. Install the coolant surge hose and clamp to the surge tank.
16. Install the battery tray.
17. Install the underhood electrical center.
18. Install and connect the battery.
19. If necessary, bleed the brake system.