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The power brake booster is a tandem vacuum suspended unit. Some
models may be equipped with a single or dual function vacuum switch
which activates a brake warning light should low booster vacuum be
present. Under normal operation, vacuum is present on both sides of the
diaphragms. When the brakes are applied, atmospheric air is admitted to
one side of the diaphragms to provide power assistance.
REMOVAL & INSTALLATION1994-97 Models
See Figures 1 and 2
When removing the master cylinder from the power brake booster, it is
not necessary to disconnect the hydraulic lines, therefore the brake
system should not have to be bled.
Apply the parking brake and block the drive wheels.
Remove the master cylinder-to-power brake booster nuts, then
reposition the master cylinder and combination valve out of the way; if
necessary, support the master cylinder on a wire to prevent damaging the
Disconnect the vacuum hose from the power brake booster.
Fig. Fig 1: Common power brake booster attachment
From under the dash, remove the retainer and washer from the brake
pedal on 1994 utility models. On all other models, remove the retainer
and brake switch from the brake pedal.
Disconnect the pushrod from the brake pedal.
From under the dash, remove the power brake booster-to-cowl retaining nuts.
Back under the hood, remove the power brake booster and the gasket from the cowl.
the booster to the cowl using a new gasket.
Install the bo
oster retaining nuts and tighten to 16 ft. lbs. (22
Nm) 1994 utility models, 24 ft. lbs. (32 Nm) on 1994 pick-up models and
27 ft. lbs. (36 Nm) on all 1995-97 models.
Connect the pedal pushrod and install the washer or switch and the retainer.
Connect the vacuum hose.
Fig. Fig. 2: Checking the piston booster rod using the gauge tool
For all vehicles cover
ed in this guide, gauge the booster rod:
Apply 25 in. Hg (85 kPa) of vacuum using a hand held vacuum pump or apply maximum engine vacuum.
k the maximum and minimum rod lengths using J-37839 or an equivalent pushrod height gauge.
If the piston is not within limits, install a service adjustable piston rod and adjust it to the correct length.
Reposition the master cylinder and combination valve bracket to
the booster studs, then secure using the retaining nuts. For details,
please refer to the master cylinder procedure located earlier in this
Start and run the engine, then check for proper booster operation.