Vacuum Brake Booster Replacement (W/O ABS)

Vacuum Brake Booster Replacement (W/O ABS)

Caution: Refer to Brake Fluid Irritant Caution .

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

Removal Procedure

1. Turn the ignition to the OFF position.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the left front tire and wheel assembly.




4. Remove the 2 nuts that attach the proportioning valve bracket to the left front wheelhouse.
5. Lower the vehicle.




6. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve (1) from the vacuum brake hose (3).




7. Remove the 4 brake pipes (1) from the proportioning valve. Use bleeder valve caps or similar rubber caps to plug the brake pipes in order to prevent brake fluid loss and contamination.




8. Remove the master cylinder nuts from the vacuum brake booster.
9. Remove the proportioning valve bracket assembly with the brake master cylinder from the vehicle.
10. Remove the closeout panel.
11. Remove the electrical connector from the brake apply sensor.




12. Remove the 2 brake pedal assembly to cowl mounting nuts.




13. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4).
Tilt the vacuum brake booster slightly in order to work the booster pushrod off the brake pedal pin. Do not apply excessive side pressure on the pushrod.
14. Remove the booster from the vehicle.

Installation Procedure





1. Install the booster to the vehicle.
2. Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the brake pedal pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.
3. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4).





Notice: Refer to Fastener Notice .

4. Install the 2 brake pedal assembly to cowl mounting nuts.

Tighten the nuts to 15 N.m (11 lb ft).

5. Install the electrical connector to the brake apply sensor.
6. Install the closeout panel.
7. Install the proportioning valve bracket assembly with the brake master cylinder to the vehicle.





Important: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears.

8. Install the master cylinder nuts to the vacuum brake booster.

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

9. Raise the vehicle.




10. Install the 2 nuts that attach the proportioning valve bracket assembly to the left wheelhouse.

Tighten the nuts to 10 N.m (86 lb in).

11. Install the left front tire and wheel assembly.
12. Lower the vehicle.




13. Remove the caps or plugs from the 4 brake pipes (1) and install the 4 brake pipes (1) to the proportioning valve.

Tighten the pipes to 20 N.m (15 lb ft).




14. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
15. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) .
16. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration . Programming and Relearning