Removal & Installation
- Disconnect the negative battery cable. Wait at least 90 seconds once the battery cable is disconnected before working on the vehicle. This will hinder the deployment of the air bags.
- Loosen the left front wheel lug nuts.
- Raise and safely support the front of the vehicle securely on jackstands.
- Remove the left front wheel.
- Unbolt and remove the master cylinder. Be sure to label all brake lines.
- Label and disconnect the vacuum hose from the brake booster.
- Remove the lower pad.
- Remove the pedal return spring. Do NOT stretch the spring.
- Detach the clip and clevis pin from the booster.
- Unbolt and remove the ignition coil and igniter assembly.
- Using a line wrench and a spanner, disconnect the brake line from the flexible hose of the left hand brake.
- Extract the brake line grommet from the body.
- Unbolt and remove the three brake lines from the No. 1 line clamp.
- From inside the vehicle, remove the four nuts and clevis then pull out the brake booster along with gasket.
- Position a new gasket on the end of the brake booster and mount on the firewall.
- Connect the hoses.
- Install the clevis to the operating rod.
- Install and tighten the booster nuts to 9 ft. lbs. (13 Nm).
- Insert the clevis pin into the clevis and brake pedal, then secure the clevis pin with the clip.
- Engage the pedal return spring.
- Attach the brake lines to the No. 1 clamp, then tighten to 48 inch lbs. (5 Nm).
- Insert the brake line grommet to the body.
Adjust the length of the brake booster push rod as follows:
- Install a new gasket on the master cylinder.
- Install a vacuum booster push rod depth gauge such as (09737-00010) or equivalent, on the master cylinder gasket and lower the pin until its tip slightly touches the piston.
- Turn the tool upside down and position it on the brake booster.
- Measure the clearance between the booster push rod and the pin head on the depth gauge tool.
- Clearance should be zero. If not, adjust the booster push rod length until the push rod lightly touches the pin head.
When adjusting the push rod, depress the brake pedal so that the push rod sticks out.
- Install the brake master cylinder.
- Connect the vacuum hose to the brake booster.
- fill the brake booster reservoir with fluid and bleed the system.
- Check for leaks.
- Check and adjust the brake pedal, then tighten the clevis lock nut to 19 ft. lbs. (25 Nm).
Perform a system operational test:
- Depress the brake pedal several times with the engine OFF and check that there is no change in the pedal reserve distance.
- Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.
System Operation Test
- 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.Vacuum Leak Test
- 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.