Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER ASSEMBLY
REMOVAL
1. REMOVE MASTER CYLINDER
2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN





5. REMOVE BRAKE BOOSTER
a. Remove the clevis from the push rod.
b. Remove the 4 booster installation nuts.
c. Remove the booster and gasket.
d. Remove the 2 stopper rings, brake booster bracket and gasket from the brake booster.

INSTALLATION
1. INSTALL BRAKE BOOSTER
a. Install a new gasket to the brake booster.
b. Install the brake booster bracket and 2 stopper rings to the brake booster.
c. Install a new gasket and the booster with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
d. Install the clevis to the operating rod.
e. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
f. Connect the vacuum hose to the brake booster.
2. ADJUST LENGTH OF BOOSTER PUSH ROD





a. Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston.
SST 09737-00011





b. Turn the SST upside down, and set it on the booster.
SST 09737-00011
c. Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)





d. Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
3. INSTALL MASTER CYLINDER
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
5. CHECK FOR FLUID LEAKAGE
6. CHECK AND ADJUST BRAKE PEDAL
7. DO OPERATIONAL CHECK