Brake Booster, Vacuum

Removal

1. Disconnect the battery cables.

2. Disconnect manifold vacuum hose from power brake booster check valve (2365) .

3. Remove the brake tubes from the primary and secondary outlet ports of the brake master cylinder (2140) .

4. Remove two nuts attaching brake master cylinder to power brake booster (2005) assembly, and remove brake master cylinder .

5. If equipped with a manual transmission, disconnect clutch cable routing bracket from body side rail and move cable toward engine to gain maneuvering room for power brake booster .

6. Disconnect accelerator cable (9A758) at dash panel (01610) and accelerator pedal and shaft (9725) and position out-of-the-way to gain maneuvering room for power brake booster .

7. Working inside vehicle below dash panel , remove stoplight switch wiring connector from stoplight switch (13480) . Remove hairpin retainer and outer nylon brake master cylinder push rod spacer (2B129) from pedal pin. Slide the stoplight switch off brake pedal pin just far enough for outer arm to clear pin. Remove stoplight switch . Be careful not to damage stoplight switch during removal.

   Slide the booster push rod brake master cylinder push rod bushing (2474) off the brake pedal pin.

8. Loosen the brake pedal support to cowl screw at least two turns. Loosen the four booster stud nuts that secure the pedal support bracket (01508) to the power brake booster and dash panel .

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

Installation

1. Working inside vehicle, install booster push rod and brake master cylinder push rod bushings on brake pedal pin.

2. Feed power brake booster into dash panel , starting with smallest dash panel hole. Feed the next stud through the slotted hole, then feed the last two studs through longer holes in dash panel .

3. Working inside vehicles, pull booster studs through holes in the pedal support bracket .

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

5. Connect manifold vacuum hose to power brake booster check valve .

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

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

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

9. Attach accelerator cable to the accelerator pedal and shaft and pedal support bracket . Secure clutch cable routing bracket to the body side rail.

10. Connect battery (10653) cables.

11. Start engine and check power brake function.