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Home >> Chevrolet >> 2002 >> C3500 HD 6.5 F, Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brakes >> Repair Instructions >> Hydraulic Brake Booster Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Booster Assembly & Bulkhead Nuts
    GM361376Courtesy of GENERAL MOTORS CORP.
  1. Install the gasket.
  2. Install the booster assembly.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the 4 booster nuts.

    Tighten:  Tighten the nuts to 36 N.m (26 lb ft).

    4. Fig 2: Pushrod, Brake Pedal Pin & Stoplamp Switch
    GM156233Courtesy of GENERAL MOTORS CORP.
  4. Install the pushrod to the brake pedal pin.
  5. Install the stoplamp switch. Refer to Stop Lamp Switch Replacement .
    6. Fig 3: View Of Booster Assembly, Wiring Harness Bracket & Spacer
    GM363525Courtesy of GENERAL MOTORS CORP.
  6. Install the spacer (3), the wiring harness bracket (2), and the master cylinder (1) to the booster assembly (4).
    7. Fig 4: View Of Master Cylinder
    GM363527Courtesy of GENERAL MOTORS CORP.
  7. Install the 2 master cylinder nuts.

    Tighten:  Tighten the nuts to 36 N.m (27 lb ft).

  8. Connect the return hose, steering gear hose, and inlet hoses.
  9. Bleed the hydraulic booster system. Refer to BLEEDING THE POWER STEERING SYSTEM in Power Steering System.
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