GM Malibu/Cutlass 1997-2000

Power Brake Booster

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REMOVAL & INSTALLATION




NOTE
It is not necessary to remove or disconnect the master cylinder from the vehicle in order to remove the vacuum booster. However, if both the vacuum booster and master cylinder are to be removed, remove the master cylinder first.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the power distribution box mounting bracket in the engine compartment and move the distribution box away from the booster.
  6.  
  7. Unfasten the master cylinder-to-booster retaining nuts.
  8.  


WARNING
Be careful not to dislodge the insulator between the booster and the front of the dash.

  1. Separate the master cylinder from the booster. Move the master cylinder forward just enough to clear the studs on the vacuum booster. This will flex the brake pipes slightly; be careful not to bend or distort the pipes.
  2.  
  3. Disconnect the vacuum hose from the vacuum check valve.
  4.  
  5. Unfasten the booster retaining nuts.
  6.  
  7. Remove the left sound insulator from the inside of the vehicle.
  8.  
  9. Disconnect the vacuum booster pushrod from the brake pedal inside the car. Tilt the entire vacuum booster slightly to work the booster pushrod off the pedal clevis pin without putting undue side pressure on the pushrod.
  10.  
  11. Remove the booster from the vehicle.
  12.  



Click image to see an enlarged view

Fig. Exploded view of the vacuum (power brake) booster mounting

To install:

  1. Position the booster in the vehicle.
  2.  
  3. Connect the booster pushrod to the brake pedal. Tilt the entire booster slightly to work the booster pushrod onto the pedal clevis pin without putting undue pressure on the pushrod. Use your free hand to align the pushrod with the pedal and push together.
  4.  
  5. Install the booster attaching nuts, then tighten them to 20 ft. lbs. (27 Nm).
  6.  
  7. Connect the booster vacuum hose to the vacuum check valve.
  8.  
  9. Position the master cylinder to the booster, install the retaining nuts, then tighten them to 20 ft. lbs. (27 Nm).
  10.  
  11. Install the power distribution box mounting bracket in the engine compartment and move the distribution box back into the bracket.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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