Jeep Wrangler/YJ 1987-1995 Repair Guide

Power Brake Booster

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REMOVAL & INSTALLATION



Without ABS

See Figures 1 and 2

For vehicles equipped with an Anti-lock Brake System (ABS), please refer to removal and installation of the power brake booster in the Anti-lock Brake portion of this section.

  1. Loosen, but do not remove, the nuts attaching the master cylinder to booster.
  2.  
  3. Remove the instrument panel lower trim cover.
  4.  
  5. Remove the retaining clip attaching the booster pushrod to the brake pedal.
  6.  
  7. Disconnect the stoplight switch electrical connector.
  8.  
  9. Remove the bolts and nuts attaching the booster to the dash panel and remove the vacuum hose.
  10.  
  11. Remove the master cylinder from the booster and carefully position it aside, being careful not to damage the brake lines. Remove the booster.
  12.  

To install:
  1. Install the check valve and grommet in the booster. Position the booster on the vehicle and install the attaching nuts and bolts.
  2.  
  3. Attach the booster pushrod to the brake pedal. Tighten the booster mounting bolts and nuts to 22-30 ft. lbs. (30-41 Nm).
  4.  
  5. Connect the stoplight switch electrical connector and reinstall the trim panels.
  6.  
  7. Install the master cylinder on the booster and tighten the nuts to 15-25 ft. lbs. (21-34 Nm). Top off the master cylinder, connect the vacuum hose and check for proper operation of the system.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Power brake booster mounting-early models without ABS



Click image to see an enlarged view

Fig. Fig. 2: Power brake booster mounting-later models without ABS

 
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