Removal and Installation: Removal

1. Turn the ignition switch OFF.
   CAUTION: Do not turn the ignition switch ON before the completion of the installation procedure.
2. Depress the brake pedal 20 times or more to release the pressure from the accumulator.
   CAUTION: Always perform this step before removing the hydraulic booster assembly.
3. Disconnect battery or batteries. Refer to Battery Disconnect .
4. Drain brake fluid. Refer to Drain and Refill .
5. Remove air cleaner and air duct assembly. Refer to Exploded View (VK56VD) or Exploded View (CUMMINS 5.0L).
6. Remove cowl top extension. Refer to Removal and Installation - Cowl Top Extension .
7. Disconnect the harness connector from the hydraulic booster assembly.
8. Disconnect the harness connector from the brake fluid level sensor.
9. Separate the brake tube from the hydraulic booster assembly with a flare nut wrench. Refer to Removal and Installation .
10. Remove brake tube from clip.
11. Separate brake tubes from ABS actuator.
12. Remove snap pin (1) and clevis pin (2) from clevis.

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13. Remove nuts on hydraulic booster assembly and brake pedal assembly.
    CAUTION: Support the hydraulic booster assembly to prevent contact with other parts.
14. Remove hydraulic booster assembly.
    CAUTION:

    • Always hold the spacer block and front part of ABS actuator and electric unit (control unit when removing the hydraulic booster assembly.
      • XD Models

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        (A)	: Front of ABS actuator and electric unit (control unit)
        (B)	: Spacer block

      • Non-XD Models

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        (A)	: Front of ABS actuator and electric unit (control unit)
        (B)	: Spacer block

    • Do not deform or bend the brake tubes when removing the hydraulic booster assembly.
    • Always use a cushion or equivalent to place the hydraulic booster assembly. Failure to do this may cause uneven loads or impact that may result in a malfunction.
15. After replacing hydraulic booster assembly, always follow the accumulator disposal procedure to discard the hydraulic booster assembly. Refer to Disposal .

ADJUSTMENT BEFORE INSTALLATION 

Input Rod Length adjustment 

1. Loosen the lock nut and adjust the input rod to the specified length.
   • XD Models

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     (1)	: Input rod
     (2)	: Lock nut
     Input rod length (A)	: Refer to Brake Booster .

   • Non-XD Models

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     (1)	: Input rod
     (2)	: Lock nut
     Input rod length (A)	: Refer to Brake Booster .

2. Tighten the lock nut to the specified torque.