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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 770 (General Hydraulic Brake System) >> Repair Instructions >> Hydraulic Brake Booster Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid.
  1. Apply the park brake.
  2. Place a drain pan under the hydraulic brake booster and the booster reservoir.
  3. Disconnect the reservoir hose from the booster.
    Fig 1: Hydraulic Brake Booster
    G02502296Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the power steering hoses from the booster.

    Important:  Do not remove the brake pipes from the master cylinder.

    5. Fig 2: Disconnecting Power Steering Hoses From Booster
    G02502297Courtesy of GENERAL MOTORS CORP.
  5. Remove the master cylinder nuts. Refer to Master Cylinder Replacement .
  6. Support the master cylinder.
  7. Disconnect the pushrod from the brake pedal. Refer to Stop Lamp Switch Replacement .
  8. Remove the hydraulic booster mounting nuts from the inside of the vehicle.
  9. Remove the booster assembly.
  10. Remove the gasket.
    Fig 3: Removing Booster Assembly
    G02502298Courtesy of GENERAL MOTORS CORP.
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