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Home >> Chevrolet >> 2005 >> Aveo Base, 4D Hatchback >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brake System >> Repair Instructions >> Vacuum Brake Booster Replacement >> Removal Procedure

Removal Procedure

    Fig 1: Disconnecting Electrical Connector From Reservoir
    GM1245647Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the electrical connector from the reservoir.
    2. Fig 2: View of Clutch Hose Connection Clip and Master Cylinder (Manual Transaxle)
    GM1245654Courtesy of GENERAL MOTORS CORP.
  2. For vehicles with a manual transaxle, disconnect the clip on the clutch hose connection to the master cylinder.
  3. Plug the clutch hose and the master cylinder so that the fluid does not escape.
    4. Fig 3: View of Booster Housing Seal and Master Cylinder
    GM1245651Courtesy of GENERAL MOTORS CORP.
  4. Remove the master cylinder attaching nuts.
  5. Push the master cylinder forward slightly and move it out of the way. Do not disconnect the brake lines.
  6. Remove and discard the booster housing seal.
    7. Fig 4: View of Clip On Vacuum Hose Connection To Booster (DOCH Engine)
    GM1245655Courtesy of GENERAL MOTORS CORP.
  7. Remove the clip on the vacuum hose connection to the booster, DOHC engine connection shown.
  8. Disconnect the brake lamp switch.
  9. Remove the brake pedal spring.
  10. Disconnect the clip and the pushrod pin from the pedal bracket assembly. Refer to Brake Pedal Assembly Replacement .
    11. Fig 5: Removal Of Booster and Support Bracket-To-Dash Panel Nuts
    GM1245656Courtesy of GENERAL MOTORS CORP.
  11. Remove the booster and the support bracket-to-dash panel nuts.
    12. Fig 6: View of Clutch Hose Connection Clip and Master Cylinder (Manual Transaxle)
    GM1245654Courtesy of GENERAL MOTORS CORP.
  12. Remove the booster and the bracket assembly from the dash panel.
    13. Fig 7: View of Booster and Bracket Nuts
    GM1245657Courtesy of GENERAL MOTORS CORP.
  13. Remove the bracket nuts from the booster and remove the booster.
    14. Fig 8: View of Rubber Boot and Retainer
    GM1245658Courtesy of GENERAL MOTORS CORP.
  14. Remove the rubber boot and the retainer.
    15. Fig 9: View of Adjustment Sleeve, Hex Nut, and Pushrod
    GM1245661Courtesy of GENERAL MOTORS CORP.
  15. Remove the pushrod.
  16. Remove the adjustment sleeve from the pushrod.
  17. Remove the hex nut.
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