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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1122 (Hydraulic Brake System) >> Repair Instructions >> Power Vacuum Brake Booster Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.
NOTE: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
    Fig 1: View Of Brake Booster Pushrod & Retaining Clip
    GM1919795Courtesy of GENERAL MOTORS CORP.
  1. Install the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if removed.
  2. Position the vacuum brake booster to the vehicle.
  3. Compress the vacuum brake booster foam filter to access the vacuum brake booster pushrod retaining clip.
  4. Connect the brake booster pushrod (1) to the booster and engage the retaining clip (2).
    5. Fig 2: Identifying J 22805-B & Locking Tab
    GM1919788Courtesy of GENERAL MOTORS CORP.
  5. Position the vacuum brake booster and the J 22805-B  (1) to the bracket. See Special Tools .
  6. Rotate the vacuum booster clockwise until the locking tab (2) engages the cowl flange.

    Ensure the booster locking tab fully engages in the bracket.

  7. Remove the J 22805-B  from the vacuum brake booster and discard the master cylinder nuts. See Special Tools .
    8. Fig 3: Identifying Vacuum Brake Booster Check Valve & Hose Assembly
    GM1919873Courtesy of GENERAL MOTORS CORP.
  8. Install the vacuum brake booster check valve and hose assembly (1).
    9. Fig 4: Removing/Installing Master Cylinder Nuts
    GM1895892Courtesy of GENERAL MOTORS CORP.
  9. Install the master cylinder to the vacuum brake booster.
    10. NOTE: Refer to Fastener Notice .
  10. Install new master cylinder nuts (1).

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

  11. Connect the master cylinder fluid level sensor electrical connector.
  12. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
  13. Install the surge tank. Refer to Radiator Surge Tank Replacement .
  14. Install the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement .
    15. Fig 5: Identifying Vacuum Brake Booster Pushrod Wave Washer
    GM1919814Courtesy of GENERAL MOTORS CORP.
  15. Install the vacuum brake booster pushrod wave washer (1).
    16. Fig 6: View Of Vacuum Brake Booster Pushrod Bushing
    GM1919812Courtesy of GENERAL MOTORS CORP.
  16. Install the vacuum brake booster pushrod bushing (1).
    17. Fig 7: View Of Vacuum Brake Booster Pushrod
    GM1919807Courtesy of GENERAL MOTORS CORP.
  17. Connect the vacuum brake booster pushrod (1) to the brake pedal pivot.
    18. Fig 8: Identifying Vacuum Brake Booster Pushrod Retaining Clip
    GM1919805Courtesy of GENERAL MOTORS CORP.
  18. Install the vacuum brake booster pushrod retaining clip (1).
    19. Fig 9: Identifying Brake Pedal Position Sensor
    GM1919797Courtesy of GENERAL MOTORS CORP.
  19. Connect the brake pedal position sensor (1) electrical connector.
  20. Install the steering column assembly. Refer to Steering Column Replacement .
  21. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .
  22. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side .
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