Power Brake Booster: Removal
- Disconnect negative (ground) cable from the battery and isolate the cable.
- Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place.
- Remove the one nut and one bolt securing the air cleaner box in place, then disconnect the wiring harness connector at the air inlet sensor.
- Lift the air cleaner box upward enough to clear its grommeted alignment post, then move the air cleaner box forward just enough to access the battery tray mounting bolts.
- Remove the 2 bolts, then the 2 nuts mounting the battery tray to its bracket. Remove the battery tray.
- Remove the master cylinder. See MASTER CYLINDER .
- If the vehicle is equipped with ABS, remove the Integrated Control Unit (ICU).
- Remove the 3 bolts securing the ICU mounting bracket to the frame rail.
- On all models, disconnect the vacuum hoses from the check valve on the power brake booster, but do not remove the check valve from power brake booster. See Fig 1.
- Locate the brake pedal-to-power brake booster input rod attachment under the instrument panel. Position a small screwdriver under the center tang of the retaining clip. Rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin. Remove the clip. See Fig 2.
- Remove the 4 nuts attaching the power brake booster to the instrument panel. The nuts are accessible from under the instrument panel in the area of the brake pedal bracket. See Fig 3.
- Slide the power brake booster forward until mounting studs clear the instrument panel. Turn the booster sideways, then remove it from the vehicle. See Fig 4.
CAUTION:
The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent contaminants from entering booster. This can be done by pumping the brake pedal 4-5 times while the engine is not running until a firm brake pedal is achieved.