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Power Brake Booster: Installation

  1. Install brake booster:
    1. Install the booster and a new gasket.
    2. Install the clevis to the brake booster push rod.
    3. Install and tighten the booster installation nuts.
    4. Install the clevis pin into the clevis and brake peal, and install the clip to the clevis in.
    5. Install the pedal return spring.
    2. NOTE: If the brake master cylinder or power brake booster is replaced, perform the following procedure.
  2. Adjust length of booster push rod:
    1. Set an appropriate measuring gauge on the master cylinder, and lower the pin until its tip slightly touches the piston. Manufacturer recommends tool (SST 09737-00011) see Fig 1.
    2. Invert the gauge, and set it on the booster.
    3. Measure the clearance between the brake booster push rod and gauge head. Allowable clearance is 0 in. (0 mm). If any clearance exists, adjust brake booster push rod until clearance between push rod and gauge is zero.
    4. Using a push rod adjuster, adjust the booster push rod length until the push rod lightly touches the pin head. Manufacturer recommends tool (SST 09737-00020). See Figure.
  3. If equipped with vehicle skid control, install recharge pump assembly. See RECHARGE PUMP ASSEMBLY .
  4. Install master cylinder. See MASTER CYLINDER .
  5. Connect vacuum hose to brake booster.
  6. Fill brake fluid reservoir and bleed brake system. See BLEEDING PROCEDURE  under BLEEDING BRAKE SYSTEM.
  7. Check for brake fluid leaks.
  8. Check and adjust brake pedal. See BRAKE PEDAL HEIGHT .
  9. Install lower No. 1 instrument panel, lower left side instrument panel insert and No. 2 heater to register duct. See INSTRUMENT PANEL under REMOVAL & INSTALLATION in INSTRUMENT PANELS - AVALON article.
  10. Perform a power brake booster operational check. See POWER BRAKE UNIT .
Fig 1: Measuring Clearance Between Master Cylinder & Push Rod
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