Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

1. Turn the ignition switch to the OFF position.

2. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.

3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (LS7 or LS9) Battery Negative Cable Disconnection and ConnectionBattery Negative Cable Disconnection and Connection (LS3) Battery Negative Cable Disconnection and Connection.

4. Disconnect the brake fluid level indicator switch electrical connector.

5. Without disconnecting the radiator surge tank inlet and outlet hoses, remove the radiator surge tank and position aside. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.





6. Disconnect the vacuum brake booster check valve (1) from the power vacuum brake booster and position aside.





7. Remove the master cylinder nuts (1).

8. Without disconnecting the brake pipe fittings, remove the master cylinder and position aside.

Secure the master cylinder in an upright position with heavy mechanics wire or equivalent.

9. Remove the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement Service and Repair.

10. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement Service and Repair.

11. Remove the telescoping steering column motor bracket and position the motor assembly to the right of the steering column. Refer to Telescope Motor Assembly Replacement Telescope Motor Assembly Replacement.





12. Remove the brake booster pushrod clevis pin retainer (1).





13. Remove the brake booster pushrod clevis pin (1).





14. Remove the power vacuum brake booster nuts (1).

Note:
The power vacuum brake booster is retained to the cowl with push-on nuts during assembly.





15. Remove the power vacuum brake booster (1).

Move the power vacuum brake booster from side-to-side to release the booster studs from the push-on nuts.

16. Remove the power vacuum brake booster gasket (2).

Inspect the gasket for damage and replace, if necessary.

Installation Procedure





1. Install the power vacuum brake booster (1) and the gasket (2) to the vehicle.

Caution:
Refer to Fastener Caution Fastener Caution.





2. Install the power vacuum brake booster nuts (1) and tighten to 27 Nm (20 lb ft).





3. Install the brake booster pushrod clevis pin (1) to the brake pedal and the power vacuum brake booster pushrod.





4. Install the brake booster pushrod clevis pin retainer (1).

Rotate the clevis pin retainer to ensure it is fully engaged in the clevis pin groove.

5. Position and install the telescoping steering column motor and bracket assembly to the steering column. Refer to Telescope Motor Assembly Replacement Telescope Motor Assembly Replacement.

6. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement Service and Repair.

7. Install the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement Service and Repair.





8. Install the master cylinder to the power vacuum brake booster.

9. Install the master cylinder nuts (1) and tighten to 18 Nm (13 lb ft).

10. Connect the brake fluid level indicator switch electrical connector.





11. Connect the vacuum brake booster check valve (1) to the power vacuum brake booster.

12. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

13. Connect the brake fluid level indicator switch electrical connector.

14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (LS7 or LS9) Battery Negative Cable Disconnection and ConnectionBattery Negative Cable Disconnection and Connection (LS3) Battery Negative Cable Disconnection and Connection.