Hydraulic Brake Booster Replacement

HYDRAULIC BRAKE BOOSTER REPLACEMENT

CAUTION: REFER TO BRAKE FLUID IRRITANT CAUTION IN SERVICE PRECAUTIONS.

NOTE:
- Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions.
- 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.

Checking And Adding Fluid
For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid in Power Steering System.

Bleeding The Hydraulic Booster System
Refer to Bleeding the Power Steering System in Power Steering System.

Flushing The Hydraulic Booster System
Refer to Flushing the Power Steering System in Power Steering System.

Removal Procedure




1. Apply the park brake and block the wheels.
2. Disconnect the inlet hose, the steering gear hose, and the return hoses from the booster assembly.
3. Remove the master cylinder retaining nuts and remove the master cylinder. Do not disconnect the brake pipes..
4. Remove the stop lamp switch retaining clip (4) from the brake pedal pin (1).
5. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal pin (1).




6. Remove the booster to bulkhead nuts.
7. Remove the booster assembly.
8. Remove the gasket.

Installation Procedure




1. Install the gasket.
2. Install the booster assembly.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the booster to bulkhead nuts.

Tighten
Tighten the nuts to 36 N.m (27 lb ft).




4. Install the stop lamp switch (2) and the pushrod (3) to the brake pedal pin (1).
5. Install the stop lamp switch retaining clip (4) to the brake pedal pin (1).
6. Install the master cylinder and the master cylinder retaining nuts.

Tighten
Tighten the nuts to 36 N.m (27 lb ft).

7. Connect the return hose, the steering gear hose, and the inlet hoses.
8. Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System.
9. Release the park brake and unblock the wheels.