Power Brake Booster LHD Cars, Replacement: Removal

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Remove bracket with hydraulic unit as per Hydraulic Unit, Replacement . Then follow instructions below.
Remove master cylinder as per Removal . Then continue as below.

Fig 1: Identifying Master Cylinder

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove non-return valve and vacuum hose from cylinder.
Remove connector from pedal sensor.
Remove ventilation hose and undo lead over power brake booster for better access.

Fig 2: Identifying Power Brake Booster Nuts And Locking Spring

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove sound insulation under steering wheel.
Remove the four nuts holding the power brake booster on the inside of the firewall.
Remove locking spring holding the support bracket to the brake pedal.

NOTE: Check car chassis no.

USA/Canada 4-door up to chassis no. 60654
USA/Canada 5-door up to chassis no. 258
Europe 4-door up to chassis no. 76400
Europe 5-door up to chassis no. 2800

In cars with chassis numbers below those above, it may happen that the pushrod seat in the brake master cylinder comes out as well on the end of the pushrod when separating the power brake booster and master cylinder. It is not allowed to reinstall the seat in the master cylinder. If seat has come out of the cylinder as well, the master cylinder must be replaced with a new one.

Fig 3: Identifying Power Brake Booster

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove power brake booster. Watch out for O-ring between power brake booster and firewall.