REMOVAL & INSTALLATION
See Figure 1
- Disconnect the negative battery cable. Firmly, set the parking brake and block the wheels.
- Remove the air cleaner and air duct. Disconnect the vacuum hose to the vacuum booster.
- Disconnect and plug the brake fluid lines at the master cylinder. Place rags under the master cylinder to catch any leaking fluid.
Be careful not to spill any brake fluid on any painted surface. Permanent damage to the paint will result.
- From inside the vehicle, remove the pedal return spring and the snapring from the clevis pin. Separate the clevis pin from the brake pedal.
- Remove the vacuum booster mounting nuts at the firewall and lift out the booster unit and master cylinder/reservoir as an assembly.
Whenever the booster or master cylinder has been removed or replaced, check and adjust the booster pushrod as follows:
- This adjustment requires the use of special tool J-34873-A booster pushrod gauge tool.
- Set the special tool on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the piston.
- Turn the special tool upside-down and position it onto the booster.
- Measure the clearance between the booster pushrod and the pin head of the tool. There must be zero clearance. To obtain ZERO clearance, adjust the pushrod length until the pushrod just contacts the head of the pin.
- Install the booster assembly into the vehicle. Torque the retaining nuts evenly to 10 ft. lbs.
- Install the clevis to the brake pedal. Install clevis pin and clip. Install brake pedal return spring.
- Install vacuum hose to the the booster assembly.
- Reconnect the lines to the master cylinder. Use the proper tool (flare wrench or line wrench) to tighten the fittings at the master cylinder.
- Install air cleaner and air duct. Reconnect the battery cable.
- Bleed the master cylinder and brake system. Road test the vehicle for proper operation.