Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Vehicle Damage Warnings) .


1. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (Underhood Electrical Center or Junction Block Replacement) .
2. Remove and position aside the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .




3. Disconnect the vacuum brake booster vacuum check valve and hose from the vacuum brake booster and position aside.
4. Remove the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement) .
5. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (Service and Repair) .




6. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement (Service and Repair) .
7. Remove the vacuum brake booster pushrod retainer (1).
8. Disconnect the vacuum brake booster pushrod from the brake pedal.




9. Remove the 4 vacuum brake booster nuts (1).




10. Carefully pull the vacuum brake booster forward until the mounting studs clear the dash panel.

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


11. Remove the vacuum brake booster (1).




12. Inspect the vacuum brake booster gasket (1) for damage and replace if necessary.



Installation Procedure





1. Install the vacuum brake booster gasket (1).

Important: Ensure the foam insulator on the mounting surface of the vacuum brake booster is properly installed on the booster.






2. While guiding the brake booster pushrod and mounting studs through the dash panel, install the vacuum brake booster (1).

Notice: Refer to Fastener Notice (Fastener Notice) .





3. Install the 4 vacuum brake booster nuts (1).

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





4. Connect the vacuum brake booster pushrod to the brake pedal.
5. Install the vacuum brake booster pushrod retainer (1).
Rotate the vacuum brake booster pushrod retainer 360 degrees to ensure it is properly installed.
6. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement (Service and Repair) .
7. Install the BPMV. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair) .
8. Install the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement) .




9. Connect the vacuum brake booster vacuum check valve and hose to the vacuum brake booster.
10. Install the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .
11. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (Underhood Electrical Center or Junction Block Replacement) .