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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1540 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
    2. Fig 1: Electrical Connections & Washer Hose At Container
    GM70094Courtesy of GENERAL MOTORS CORP.
  2. Remove the washer solvent container retaining nuts.
  3. Lift the washer solvent container from the left wheelhouse.
  4. Disconnect the electrical connections and the washer hose from the container.
  5. Plug the washer pump outlet.
    6. Fig 2: View Of Brake Fluid Level Sensor Electrical Connector
    GM675866Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the electrical connector (1) from the brake fluid level sensor.
    7. Fig 3: View Of Master Cylinder & Mounting Nuts
    GM63941Courtesy of GENERAL MOTORS CORP.
  7. Remove the nuts securing the master cylinder to the brake booster.
  8. Remove the master cylinder from the brake booster without disconnecting the brake pipes and position the master cylinder aside.
    9. Fig 4: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the brake booster vacuum hose from the booster check valve.
  10. Remove the instrument panel lower trim panel. Refer to Trim Panel Replacement - Knee Bolster in Instrument Panel, Gages, and Console.
    11. Fig 5: Isolation Mat To Brake Pedal
    GM63944Courtesy of GENERAL MOTORS CORP.
  11. Remove the retainer, washer, brake pedal pin, and brake booster pushrod from the brake pedal.
    12. Fig 6: Motor Assembly To Right Of Steering Column
    GM425435Courtesy of GENERAL MOTORS CORP.
  12. Remove the screw (3) from the telescoping column motor mounting bracket (5), if equipped.
  13. Position the motor assembly to the right of the steering column.
    14. Fig 7: Brake Booster Mounting Nuts & Washers To Booster Studs
    GM63943Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The brake booster is retained to the cowl with push-on nuts.
  14. Remove the brake booster mounting nuts and washers from the booster studs.
  15. In order to remove the booster from the cowl, perform the following steps:
    • In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
    • Pull the booster straight out.
  16. Remove the brake booster and seal from the cowl.
  17. Inspect the booster seal and sealing surfaces for damage. Replace the seal if necessary.
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