How do you change the power brake booster?? The bolts inside the cab on the firewall are easy enough to figure out as is detaching the master cylinder, but how do disconnect the "plunger" or whatever the part is called that's connected to the brake pedal??
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Hi Michelle, Im AL the owner of Big As Auto Repair.
This is an easy task with the correct tools.
First, pump the brakes 20 times with the key off. Next, remove the 2 nuts that hold the master cylinder in place. Next, pull the master cylinder back and out of the brake booster. Next, go inside the vehicle and on the brake pedal arm you see the brake booster rod attached to the brake pedal arm by a retainer clip. Next, remove the clip and slide the rod away from the pedal arm. Next, around the brake booster rod at the firewall you'll see 4 nuts you'll need to remove those 4 nuts then push the booster backward out of the firewall. Next, go back under the hood and pull the booster past the master cylinder. NOTE: You should have enough room to force the booster past the master cylinder. Replace the new booster and hook up the vacuum hose and your done. Hope this helps and please visit my auto-repair-website here: http://www.bigasautorepair.com/
You will need to replace the booster. Unbolt the master cylinder from the front of the booster under the hood, then go inside of the cab and under the dash unhook the actuator rod from the brake pedal and remove the 4 nuts that hold the booster to the firewall. Then make sure to unplug the vacuum line from the booster under the hood and pull the master cylinder off of the booster being careful not to kink the brake lines. The booster should come right off.
Slide the tube nut wrench over the brake line to the master cylinder connection. The master cylinder is normally on the driver's side of the engine bay and mounted on the firewall. Orient the wrench so that it fits over the tube nut on the end of the brake line.
2Disconnect the brake line. Turn the nut counterclockwise to remove. Note the location of each brake line. There are four lines total, and they need to be put back in the same location when reinstalling the lines. You may want to mark them with masking tape and permanent marker.
3Unplug the master cylinder cap electrical plug.
4Remove the brake master cylinder to brake booster bolts with a socket wrench.
5Back the master cylinder off the brake booster.
6Unbolt the bolts holding the brake booster to the firewall on your vehicle.
7Pull the cotter pin out of the brake pedal to brake booster connecting pin with a pair of pliers. This is done inside the vehicle down in the driver side foot well.
8Pull the brake pedal to brake booster connecting pin out to disconnect the brake pedal from the brake booster connecting arm.
9Mark and remove the vacuum hoses on the brake booster and slide the booster off the firewall.
10Install the new brake booster. Installation is the reverse of removal
REMOVAL & INSTALLATION NOTE: Make sure that the booster rubber reaction disc is properly installed if the master cylinder push rod is removed or accidentally pulled out. A dislodged disc may cause excessive pedal travel and extreme operation sensitivity. The disc is black compared to the silver colored valve plunger that will be exposed after the push rod and front seal is removed. The booster unit is serviced as an assembly and must be replaced if the reaction disc cannot be properly installed and aligned, or if it cannot be located within the unit itself.
Disconnect the stop lamp switch wiring to prevent running the battery down.
Support the master cylinder from the underside with a prop.
Remove the master cylinder-to-booster retaining nuts.
Loosen the clamp that secures the manifold vacuum hose to the booster check valve, and remove the hose. Remove the booster check valve.
Pull the master cylinder off the booster and leave it supported by the prop, far enough away to allow removal of the booster assembly.
From inside the cab on vehicles equipped with push rod mounted stop lamp switch, remove the retaining pin and slide the stop lamp switch, push rod, spacers and bushing off the brake pedal arm.
From the engine compartment remove the bolts that attach the booster to the dash panel.
Mount the booster assembly on the engine side of the dash panel by sliding the bracket mounting bolts and valve operating rod in through the holes in the dash panel.
NOTE: Make certain that the booster push rod is positioned on the correct side of the master cylinder to install onto the push pin prior to tightening the booster assembly to the dash.
From inside the cab, install the booster mounting bracket-to-dash panel retaining nuts.
Position the master cylinder on the booster assembly, install the retaining nuts, and remove the prop from underneath the master cylinder.
Install the booster check valve. Connect the manifold vacuum hose to the booster check valve and secure with the clamp.
From inside the cab on vehicles equipped with push rod mounted stop lamp switch, install the bushing and position the switch on the end of the push rod. Then install the switch and rod on the pedal arm, along with spacers on each side, and secure with the retaining pin.
Connect the stop lamp switch wiring.
Start the engine and check brake operation.
Fig. 1: Check the booster pushrod adjustment using a gauge with the shown dimensions
Fig. 2: Exploded view of the typical power brake booster
Fig. 3: Booster vacuum hose connections - 2.3L & 2.9L
Fig. 4: Booster vacuum hose connections for the 4.0L
Pull the vacuum hose off the booster. Disconnect the brake lines from the master cylinder.Remove the master cylinder. Remove the windshield wiper motor if it's in the way. Inside the car, disconnect the stoplight switch connector. Slide the stop lamp switch off the brake pedal just far enough for the outer arm to clear the pin.If you have cruise control, remove the speed amplifier.Remove the booster attaching bolts/nuts. Slide the booster pushrod, bushing and the nylon washer off the brake pedal pin.In the engine compartment, pull the booster forward and rotate it until it is free. Good luck!
Pretty simple repair.I even did this alone. DO NOT disconnect the brake lines unless you are changing the master cylinder out with it. Unbolt the master cylinder and move it forward slightly. From inside the truck,unbolt the brake pedal from the rod, leave the pedal hanging. Remove the 4 bolts at the firewall that retain the booster.From outside the truck reach in and draw the old booster out.You may have to move the master cylinder up or down to clear the booster. The rod to the brake pedal will come out with the booster,make sure you put it back on the new one.