Removal & Installation
- Remove the air cleaner assembly.
- Remove the master cylinder reservoir and master cylinder. Please refer to Master Cylinder, Removal and Installation for the procedure.
- Remove the ABS hydraulic anti-lock actuator assembly. Please refer to Anti-Lock Brake System, Hydraulic Anti-Lock Actuator Assembly, Removal and Installation for the procedure.
- Disconnect the vacuum hose from the power brake booster.
- Inside of the passenger compartment, remove the spring clip from the brake pedal clevis pin. Remove the pin.
- Remove the four power brake booster nuts.
- Remove the power brake booster from the vehicle.
- Remove the push rod pivot bracket from the brake pedal-to-booster push rod.
- The installation is the reverse of removal, but please note the following important steps.
- After installing the push rod pivot bracket on the new brake pedal-to-booster push rod, check and adjust the push rod length. The length should be approximately 4.75 inches (120mm) from the face of the booster to the center of the push rod hole.
- Before installing the booster, check and adjust the booster-to-master cylinder push rod length, if needed. With a hand vacuum pump, apply approximately 20 in. Hg (50cm Hg) of vacuum to the booster. Apply 4.4 lbs. (19.6 N) of pressure to the end of the push rod and measure the length from the face of the booster to the end of the push rod. The length should be 0.405 - 0.414 inch (10.275 - 10.525mm).
- When installing the power brake booster nuts, tighten them to 9 - 12 ft. lbs. (13 - 16 Nm).
When installing the vacuum hose, make sure that it is pushed onto the booster fitting at least 1 inch (24mm).
- With the engine OFF , pump the brake pedal until the supply vacuum is entirely gone.
- Put light, steady pressure on the brake pedal.
- Start the engine and let it idle. If the system is operating correctly, the brake pedal should fall toward the floor if the constant pressure is maintained.
Power brake systems may be tested for hydraulic leaks just as ordinary systems are tested.
- Operate the engine at idle without touching the brake pedal for at least one minute.
- Turn off the engine and wait one minute.
- Test for the presence of assist vacuum by depressing the brake pedal and releasing it several times. If vacuum is present in the system, light application will produce less and less pedal travel. If there is no vacuum, air is leaking into the system.