Brake Booster

Removal

 WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in Section 100-00 . Failure to follow this instruction may result in serious personal injury.

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1. • To install, tighten to 63 Nm (46 lb-ft).

Vehicles equipped with 3.5 L Ti-VCT , 3.7L Ti-VCT or 2.0L Gasoline Turbocharged Direct Injection (GTDI) engines

2. Remove the Air Cleaner (ACL) outlet pipe. Refer to Section 303-12 .

3. Remove the Hydraulic Control Unit (HCU). Refer to Section 206-09 .

Vehicles equipped with 3.5L GTDI engine

4. • To install, tighten the nut to 6 Nm (53 lb-in).
   • To install, tighten the clamps to 5 Nm (44 lb-in)

5. Disconnect the ABS module electrical connector.

All vehicles

6. Remove the brake master cylinder. Refer to Section 206-06 .

9. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

   Remove the stoplamp switch. Refer to Section 417-01 .

10. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used. Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.

11. • To install, tighten the new nuts to 25 Nm (18 lb-ft).

Installation

1. To install, reverse the removal procedure.