Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) (Service and Repair)Battery Negative Cable Disconnection and Connection (7.0L) (Service and Repair) .




2. Remove the protective cap on the radiator surge tank upper stud.
3. Remove the radiator surge tank upper nut.
4. Loosen the radiator surge tank side nut.

Important: DO NOT remove the radiator surge tank inlet and outlet hoses.


5. Lift the radiator surge tank upward and position it forward.




6. Disconnect the electrical connector (1) from the brake fluid level sensor.




7. Remove the nuts securing the master cylinder to the brake booster.
8. Remove the master cylinder from the brake booster without disconnecting the brake pipes and position the master cylinder aside.




9. Disconnect the brake booster vacuum hose from the booster check valve.
10. Remove the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair) .
11. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement (Brake Pedal Position Sensor Replacement) .




12. Remove the retainer, washer, brake pedal pin, and brake booster pushrod from the brake pedal.




13. Remove the screw (3) from the telescoping column motor mounting bracket (5), if equipped.
14. Position the motor assembly to the right of the steering column.




15. Remove the brake booster mounting nuts and washers from the booster studs.
Important: The brake booster is retained to the cowl with push-on nuts.



16. In order to remove the booster from the cowl, perform the following steps:

* In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
* Pull the booster straight out.

17. Remove the brake booster and seal from the cowl.
18. Inspect the booster seal and sealing surfaces for damage. Replace the seal if necessary.



Installation Procedure





1. Install the seal and brake booster to the front of dash.

Notice: Refer to Fastener Notice (Fastener Notice) .

2. Install brake booster mounting nuts and washers to the booster studs.

Tighten the brake booster mounting nuts to 27 N.m (20 lb ft).





3. Install the brake booster pushrod, brake pedal pin, washer, and retainer to the brake pedal. Verify proper engagement of the retainer to the brake pedal by rotating the retainer.
4. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement (Brake Pedal Position Sensor Replacement) .




5. Reposition the telescoping column motor assembly to the steering column, if equipped.
6. Install the screw (3) to the motor mounting bracket (5).

Tighten the screw to 7 N.m (62 lb in).

7. Install the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair) .




8. Connect the brake booster vacuum hose to the brake booster check valve.




9. Install the master cylinder to the brake booster.
10. Install the master cylinder mounting nuts.

Tighten the master cylinder mounting nuts to 29 N.m (21 lb ft).





11. Connect the electrical connector (1) to the brake fluid level sensor.




12. Position the radiator surge tank to the mounting studs.
13. Install the radiator surge tank upper nut,

Tighten the radiator surge tank upper and side nuts to 8 N.m (71 lb in).

14. Install the protective cap on the radiator surge tank upper stud.
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) (Service and Repair)Battery Negative Cable Disconnection and Connection (7.0L) (Service and Repair) .
16. Program the transmitters. Refer to Transmitter Programming (N. America and Japan, except Canada) (Programming and Relearning)Transmitter Programming (Canada and Europe) (Programming and Relearning) .