Power Brake Booster

REMOVAL & INSTALLATION

1. Remove the brake master cylinder.
2. Disconnect the vacuum hose from the brake booster.
3. To disconnect the brake pedal from the booster clevis, first remove the clip. Loosen the lock nut, then remove the clevis pin.

   Fig. 2: Remove the clip to slide the clevis pin out of the pedal clevis

4. Remove the 4 mounting nuts, clevis and extract the booster from the firewall. Discard the gasket.

   To install:

5. Position a new gasket and install the booster to the firewall, secure the retaining nuts to 9 ft. lbs. (13 Nm).
6. Install the clevis pin to the clevis through the brake pedal and secure the pin with the clip.

   Fig. 3: Install the tool on top of the gasket as shown

   Fig. 4: Set the tool on the gasket, then lower the pin until its tip slightly touches the piston

7. Adjust the length of the booster pushrod:
   1. Install the gasket for the master cylinder.
   2. Set the push pin SST 09737–00010 or equivalent, on the gasket and lower the pin until its tip slightly touches the piston.
   3. Turn the tool upside down, and position it on the booster.
   4. Measure the clearance between the booster pushrod and pin head of the tool. Clearance should be 0 inch (0mm).
   5. Adjust the booster pushrod length until the pushrod lightly touches the pin head.

      NOTE: When adjusting the pushrod, depress the brake pedal so that the rod sticks out.

8. Install the master cylinder.
9. Connect the vacuum hose to the booster.
10. Fill the brake master cylinder reservoir with brake fluid and then bleed the brake system.
11. Check for fluid leakage.
12. Do an operational test.