Brake Booster, Removing and Installing (Vehicles As of Model Year 2000)

Brake booster, removing and installing (vehicles as of model year 2000)

Special tools, testers and auxiliary items required





^ Door adjusting wrench 3320





^ Release tool T10006 A

Removing
- Remove driver side trim cover.
- Remove/pull back brake light switch and, if necessary, brake pedal switch.
- Place lint-free cloths in plenum chamber in the area of the brake master cylinder.
- Connect bleeder bottle hose to left front brake caliper bleeder screw and open bleeder screw.
- By operating the brake pedal, pump out enough brake fluid until the level in the brake fluid reservoir has sunk below the supply hose.
- Close left front bleeder screw.





- Pull off clutch master cylinder supply hose - 1 - and seal with a plug.
- Disconnect connection from the Brake Fluid Level Warning Switch F34 - 2 -.
- Remove bolt - 3 -.
- Remove brake fluid reservoir - 4 - by pressing locking tabs on the reservoir downward and simultaneously pulling the brake fluid reservoir out of the sealing plugs.





- Disconnect brake lines - 1 - at brake master cylinder and plug brake lines with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Remove bolts - 2 -, Torx socket head T45 with the door adjusting wrench 3320 from the brake booster.
- Disconnect vacuum hose from brake booster.





- Press brake pedal in direction of brake booster and hold.
- Insert release tool T10006 A and pull in direction of driver seat. When doing this, counter hold on brake pedal. (At this moment the pedal must not be allowed to move backward). The mounting retaining lugs - 3 - will thereby be pressed off the ball plunger of the push rod - 2 -.
1 - Brake pedal
2 - Push rod
3 - Retaining lugs

Note: For ease of illustration separating the brake pedal from the brake servo is shown with the pedal cluster removed.

- Pull release tool T10006 A and brake pedal together toward the driver seat. (The brake pedal will thereby be pulled off the ball plunger of the push rod).
- Pull brake pedal out of push rod
- Remove brake booster with brake master cylinder from plenum chamber.

Installing
- Installation is in reverse order of removal.

Observe the following points when installing:

Joining brake pedal to brake booster
- Hold push rod ball plunger in front of mounting and push brake pedal in direction of brake booster, so the ball plunger locates audibly.
- After installing, bleed brakes.
- Adjust brake light switch, as well as brake pedal switch.