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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 755 (Hydraulic Brake System) >> Repair Instructions >> Power Vacuum Brake Booster Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Apply and release the brake pedal several times until it becomes firm to deplete the brake booster vacuum reserve.
  3. Disconnect the vacuum power brake vacuum sensor electrical connector, if equipped.
  4. Remove the vacuum power brake booster check valve and hose assembly from the brake booster grommet.
  5. Without disconnecting the wiring harness connectors, reposition the electrical center and the powertrain control modules from the underhood electrical center bracket and remove the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement .
  6. Disconnect the brake fluid level indicator switch electrical connector.
    7. Fig 1: Identifying Master Cylinder Mounting Nuts
    GM1912323Courtesy of GENERAL MOTORS CORP.
  7. Remove the master cylinder nuts (1).
  8. Disconnect the master cylinder clutch hose quick connect from the clutch master cylinder, if equipped.

    Plug the master cylinder clutch hose outlet and cap the clutch master cylinder inlet port to prevent brake fluid loss and contamination.

  9. Without disconnecting the brake pipe fittings, remove and position aside the master cylinder and support with heavy mechanics wire or equivalent.
    10. Fig 2: Locating Brake Pedal Pushrod Nut
    GM1912299Courtesy of GENERAL MOTORS CORP.
  10. Remove the steering column opening filler. Refer to Steering Column Opening Filler Replacement .
  11. Remove the brake pedal pushrod nut (1).
    12. Fig 3: Identifying Brake Pedal Pushrod Washer
    GM1912300Courtesy of GENERAL MOTORS CORP.
  12. Remove the brake pedal pushrod washer (1).
  13. Remove the brake pedal pushrod from the brake pedal pivot pin.
    14. Fig 4: Identifying Brake Booster Nuts
    GM1912303Courtesy of GENERAL MOTORS CORP.
  14. Remove the vacuum brake booster nuts (1).
    15. Fig 5: Identifying Power Brake Vacuum Booster
    GM1912326Courtesy of GENERAL MOTORS CORP.
  15. Remove the power brake vacuum booster (1).
    16. Fig 6: Identifying Power Brake Vacuum Booster Gasket
    GM1912328Courtesy of GENERAL MOTORS CORP.
  16. Remove the power brake vacuum booster gasket (1).

    Inspect the power brake vacuum booster gasket for damage and replace if necessary.

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