Brake Booster, Vacuum

5.0L Engine

Removal

1. Remove engine air cleaner, and disconnect the battery.

2. Disconnect manifold vacuum hose from booster check valve.

3. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder.

4. Remove two nuts attaching master cylinder to brake booster assembly, and remove master cylinder.

5. Working inside vehicle below instrument panel, remove stoplamp switch wiring connector from stoplamp switch. Remove hairpin retainer and outer nylon washer from pedal pin. Slide the stoplamp switch off brake pedal pin just far enough for outer arm to clear pin. Remove stoplamp switch. Be careful not to damage stoplamp switch during removal. Remove booster-to-dash panel retaining nuts.

   Vehicles equipped with speed control: Remove and set aside the control amplifier which is mounted to the lower outboard booster stud. Slide the booster push rod bushing off the brake pedal pin.

6. Inside the engine compartment, move booster forward until the booster studs clear the dash panel. Rotate front of booster inboard (toward engine), and remove booster by raising up until clear.

Installation

1. Place booster in position on dash panel.

2. Working inside vehicle, install booster push rod and bushings on brake pedal pin.

   Vehicles equipped with speed control: Place speed control amplifier bracket over lower outboard booster stud and position bracket locating tab in hole provided in brake pedal support.

   Install booster-to-dash panel retaining nuts. Tighten to 21-29 Nm (16-21 lb-ft). Position stoplamp switch so that it straddles booster push rod with stoplamp switch slot toward pedal blade and hole just clearing pin. Slide stoplamp switch completely onto pin. Be careful not to bend or deform switch. Install nylon washer on pin, and secure all parts to pin with hairpin retainer. Make sure retainer is fully installed and locked over pedal pin. Install stoplamp switch wiring connector on stoplamp switch.

3. Connect manifold vacuum hose to booster check valve.

4. Install master cylinder assembly to booster studs. Tighten to 21-29 Nm (16-21 lb-ft).

5. Install brake tube fittings into ports. Tighten to 14-24 Nm (11-17 lb-ft).

6. Bleed brake system as outlined in Section 06-06.

7. Start engine and check power brake function.
   
   
   
   
   

   Item	Part Number	Description
   1	2A032	Master Cylinder Assy
   2	2B450	Spacer
   3	2501508	Assy
   4	45265-S2	J-Nut
   5A	57048-S2	Screw
   6A	385759-S2	Nut (4 Req'd)
   7	2005	Booster Assy
   8A	382802-S100	Nut (2 Req'd)
   9B	N610957-S2	Screw
   10	9C961	Bracket
   11	—	Vacuum Tube
   12	—	Speed Control Dump Valve
   13	9C962	Retainer
   14	—	Speed Control Adapter
   15	9C962	—
   16	2455	Pedal Assy
   17	N800197-S2	Bushing
   18C	N620481-S2	Nut
   19	N800661-S2	Bolt
   20	13480	Assy
   21	2B129	Bushing (2 Req'd)
   22	2457	Cover
   23	2A309	Spacer
   24	2B195	Push Rod Assy
   25	N800196	Spacer (2 Req'd)
   26	380699-S100	Pin
   A		Tighten to 18-34 Nm (13-24 Lb-Ft)
   B		Tighten to 8-13.6 Nm (6-10 Lb-Ft)
   C		Tighten to 14-27 Nm (10-20 Lb-Ft)

2.3L Engine

Removal

Refer to illustration following Brake Booster, Vacuum, 5.0L Engine.

1. Disconnect battery ground cable.

2. Disconnect accelerator cable from throttle body.

3. Remove screw that secures accelerator cable to accelerator shaft bracket, and remove cable from bracket.

4. Remove two screws that secure accelerator shaft bracket to manifold, and rotate bracket toward engine.

5. Remove horn.

    CAUTION: The fuel system is under pressure and must be bled prior to disconnecting the quick connect fittings. Refer to Section 03-13.

6. Disconnect two manifold injector connectors located near oil dipstick retaining bracket.

7. Disconnect two fuel hoses to fuel supply manifold assembly.

8. Remove three bolts holding the oil dipstick bracket to upper intake manifold. Remove dipstick and bracket.

9. Remove windshield wiper motor.

10. Remove vacuum line hoses directly over brake booster at dash panel vacuum tee.

11. Remove bolt holding clutch cable stand, move bracket to side rail at fender inner panel.

12. If equipped with speed control, move speed control cable aside to clear booster.

13. Disconnect manifold vacuum hose from booster check valve.

14. Remove brake tubes from the primary and secondary outlet ports of master cylinder.

15. Remove two nuts retaining master cylinder to brake booster assembly, and remove master cylinder.

16. Working inside vehicle below instrument panel, remove stoplamp switch wiring connector from switch. Remove hairpin retainer and outer nylon washer from pedal pin. Slide stoplamp switch off brake pedal pin just far enough for outer arm to clear pin. Remove stoplamp switch. Be careful not to damage switch during removal. Remove booster-to-dash pedal retaining nuts.

    Vehicles equipped with speed control: Remove and set aside the control amplifier which is mounted to the lower outboard booster stud. Slide the booster push rod, bushing, and the inner nylon washer off the brake pedal pin.

17. Inside the engine compartment, move booster forward until the booster studs clear the dash panel, then rotate front of booster inboard (toward engine), and remove booster by raising up until clear.

Installation

1. Place booster in position on dash panel.

2. Working inside vehicle, install inner nylon washer, booster push rod and bushings on brake pedal pin.

   Vehicles equipped with speed control: Place speed control amplifier bracket over lower outboard booster stud and position bracket locating tab in hole provided in brake pedal support.

   Secure the booster-to-dash panel retaining nuts, and tighten to 21-29 Nm (16-21 lb-ft). Position stoplamp switch, so that it straddles booster push rod with switch slot toward pedal blade and hole just clearing pin. Slide stoplamp switch completely onto pin. Be careful not to bend or deform switch. Install nylon washer on pin, and secure all parts to pin with hairpin retainer. Make sure retainer is fully installed and locked over pedal pin. Install stoplamp switch wiring connector on stoplamp switch.

3. Connect manifold vacuum hose to booster check valve.

4. Install master cylinder assembly to booster studs. Tighten to 21-29 Nm (16-21 lb-ft).

5. Install brake tube fittings into ports. Tighten to 14-24 Nm (10-17 lb-ft).

6. Place accelerator shaft bracket in position on engine, and secure two bolts.

7. Route accelerator cable bracket to shaft bracket with a screw.

8. Connect accelerator cable to throttle body.

9. Replace horn.

10. Connect battery ground cable.

11. Install the oil dipstick tube bracket assembly to upper intake manifold. Connect two wiring connectors.

12. Install windshield wiper motor.

13. Connect fuel line supply and return hoses to fuel supply manifold assembly. Refer to Section 03-13.

14. Connect clutch cable stand off bracket to side rail.

15. Connect vacuum line hoses to vacuum tee over brake booster.

16. If moved, reroute speed control cable.

17. Bleed brake system as outlined in Section 06-06.

18. Start engine and check power brake function.