Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Special Tools

J-22805-B - Brake Booster Holder

Removal Procedure

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

3. Disconnect the brake fluid level indicator switch electrical connector.





4. Remove the power brake booster vacuum sensor (1) from the power vacuum brake booster.

5. Disconnect the power brake vacuum booster hose quick connect (2) from the power brake booster pump.

6. Position the power brake booster vacuum hose and check valve assembly upward.





7. Remove the master cylinder nuts (1).

8. Without disconnecting the brake pipes, remove and position aside the master cylinder.

9. Secure the master cylinder in an upright position and secure with heavy mechanics wire.

10. Wrap a shop cloth around the inboard stud on the power vacuum brake booster to protect the stud threads.

Note:
Position the tool against the top of the inboard power vacuum brake booster stud.

11. Install the J-22805-B - Brake Booster Holder to the opposite power vacuum brake booster stud and secure using a master cylinder nut.





12. Levering against the inboard power vacuum brake booster stud, press the locking tab (1) and rotate the J-22805-B - Brake Booster Holder (2) counter clockwise.

13. Carefully pull the power vacuum brake booster forward slightly and support the booster to access the brake booster pushrod retaining clip.





14. Release the retaining clip (1) and disengage the power vacuum brake booster input rod from the brake booster pushrod (2).

15. Remove the power vacuum brake booster from the vehicle.

Installation Procedure





1. Install the power vacuum brake booster to the vehicle.

2. Release the retaining clip (1) and engage the power vacuum brake booster input rod to the brake booster pushrod (2).

3. Press the retaining clip into position on the brake booster pushrod





4. Position the power vacuum brake booster to the vehicle front of dash.

Note:
Position the tool against the underside of the inboard power vacuum brake booster stud.

5. With a shop cloth wrapped around the inboard power vacuum brake booster stud, install the J-22805-B - Brake Booster Holder to the opposite power vacuum brake booster stud.

6. Secure the J-22805-B - Brake Booster Holder using a master cylinder nut.

7. Levering against the inboard power vacuum brake booster stud, press the locking tab (1) and rotate the J-22805-B - Brake Booster Holder (2) clockwise.

8. Ensure the locking tab is fully engaged in the power vacuum brake booster mounting plate on the front of dash.

9. Remove the J-22805-B - Brake Booster Holder and discard the master cylinder nuts.





10. Install the master cylinder to the power vacuum brake booster.

Caution:
Refer to Fastener Caution Fastener Caution.

11. Install new master cylinder nuts (1) and tighten to 33 Nm (24 lb ft).





Note:
A small amount of denatured alcohol may be used as a lubricant for assembly.

12. Install the power brake booster vacuum sensor (1) to the power vacuum brake booster.

13. Connect the power brake vacuum booster hose quick connect (2) to the power brake booster pump.

14. Connect the brake fluid level indicator switch electrical connector.

15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

16. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.