Diesel Data: Automotive Repair
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Vacuum Brake Booster: Service and Repair




Brake Booster









Removal and Installation

1. Remove the brake master cylinder. For additional information, refer to Brake Master Cylinder in Hydraulic Brake Actuation Brake Master Cylinder.

2. NOTICE: Do not service the brake pedal without first removing the stoplamp switch. Remove this switch with the brake pedal in the at-rest position. Attempting to remove this switch when the plunger is extended (during pedal apply) results in damage to the switch.

Remove the stoplamp switch. For additional information, refer to Exterior Lighting Service and Repair.

3. NOTICE: Do not service the brake pedal without first removing the cruise control deactivator switch. Remove this switch with the brake pedal in the at-rest position. Attempting to remove this switch when the plunger is extended (during pedal apply) results in damage to the switch.

Remove the cruise control deactivator switch. For additional information, refer to Cruise Control Cruise Control Deactivator Switch.

4. NOTE: The brake booster push rod clevis locking pin is a one-time use only part. Any time the brake booster push rod clevis locking pin is removed, install a new brake booster push rod clevis locking pin.

NOTE: Use an 11 mm, 12-point socket or wrench to compress the 2 locking tabs on the brake booster push rod clevis locking pin.

Remove and discard the brake booster push rod clevis locking pin, then position the brake booster push rod aside.

5. Remove the 4 brake booster nuts.
- To install, tighten to 25 Nm (18 lb-ft).

6. Remove the brake booster.

7. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch and cruise control deactivator switch. Install these switches with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position results in incorrect adjustment and damages the switches.

To install, reverse the removal procedure.

8. Verify correct stoplamp switch and cruise control deactivator switch installation. For additional information, refer to Brake Pedal Switch Adjustment in Vehicle Dynamic Systems Adjustments.

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