GM Corvette 1984-1996 Repair Guide

Power Brake Booster

Print

REMOVAL & INSTALLATION



1984-89 Vehicles

See Figure 1

  1. Unbolt the master cylinder from the power booster and position it aside. You do not have to disconnect the fluid lines, unless necessary for access.
  2.  
  3. Disconnect the vacuum hose from the check valve.
  4.  
  5. Remove the pushrod end of the valve assembly from the brake pedal by removing the retaining clip.
  6.  
  7. Unfasten the nuts from the tie rods.
  8.  
  9. Remove the power booster assembly from the cowl.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of power booster assembly-1984-89 vehicles

To install:
  1. Position the power booster assembly to the cowl.
  2.  
  3. Install the retaining nuts on the tie rods and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the pushrod end of the valve assembly to the brake pedal and install the retaining clip.
  6.  
  7. Attach the vacuum hose to the vacuum check valve.
  8.  
  9. Install the master cylinder to the power booster and tighten the retaining nuts.
  10.  
  11. If the brake lines were disconnected, bleed the brake system as outlined later in this section.
  12.  

1990-96 Vehicles

See Figures 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ECM, then remove the ECM housing bracket attaching bolt.
  4.  
  5. Remove the cruise control cable from the cruise control servo and the servo mounting bracket.
  6.  
  7. Disengage the pressure differential sensor electrical connector and the vacuum hose.
  8.  
  9. Disengage the master cylinder warning switch electrical connector, then remove the nuts attaching the master cylinder to the power booster assembly.
  10.  
  11. Reposition the master cylinder assembly, cruise control cable and the battery cable aside. Be careful not to damage the hydraulic lines.
  12.  
  13. Remove the power booster vacuum check valve from the power booster assembly.
  14.  
  15. Remove the instrument panel left sound insulator.
  16.  
  17. Remove the input pushrod assembly retaining ring and washer from the brake pedal.
  18.  
  19. For the VIN P engine, remove the nuts and washers from the tie rods.
  20.  
  21. Remove the power booster assembly attaching nuts and washers, then remove the power booster with seals and the ECM bracket attached, while disengaging the input pushrod assembly.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the brake power booster-1990 vehicle shown



Click image to see an enlarged view

Fig. Fig. 3: Power booster assembly mounting-1996 vehicle shown

To install:
  1. Install the seals, ECM bracket and power booster assembly to the brake pedal bracket. Have an assistant engage the pushrod assembly onto the brake pedal while installing the booster.
  2.  
  3. Install the booster assembly retaining nuts and tighten to 15 ft. lbs. (21 Nm).
  4.  
  5. Install the washer and retaining clip to the brake pedal, then install the left sound insulator.
  6.  
  7. Connect the vacuum check valve to the power booster assembly.
  8.  
  9. Position the master cylinder, cruise control cable bracket and the battery cable clip, then install the retaining nuts and tighten to 13 ft. lbs. (18 Nm).
  10.  
  11. Engage the master cylinder warning switch electrical connector.
  12.  
  13. Engage the pressure differential sensor electrical connection and vacuum hose.
  14.  
  15. Connect the cruise control cable to the servo and the mounting bracket.
  16.  
  17. Install the ECM housing bracket bolt and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the ECM.
  20.  
  21. Connect the negative battery cable.
  22.  

 
label.common.footer.alt.autozoneLogo