Power Brake Booster Replacement Commercial

Notice: Power steering fluid and brake fluid cannot be mixed. If brake seals contact power steering fluid or steering seals contact brake fluid, seal damage will result.

Bleed the hydraulic booster system any time you open the system. Refer to Power Steering System Bleeding -Process or -Special Conditions in Power Steering System.

Refer to Power Steering System Flushing in Power Steering System.

Refer to: Power Steering Hoses Replacement

Refer to Power Steering Pump Replacement -4.3L and 5.7L, Power Steering Pump Replacement -6.5L (Diesel), or Power Steering Pump Replacement -7.4L.

1. Apply the parking brake.
2. Disconnect the hoses from the booster assembly.
3. Remove the master cylinder mounting nuts.
4. Remove the master cylinder.

Support the master cylinder.




5. Remove the pushrod retainer.
6. Remove the retaining clip.



7. Remove the washer.



8. Remove the booster pushrod.



9. Remove the booster mounting nuts.
10. Remove the booster assembly.

1. Install the booster assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the booster mounting nuts.

Tighten
Tighten the nuts to 36 N·m (27 lb ft).




3. Install the booster pushrod.



4. Install the washer.



5. Install the retaining clip.
6. Install the pushrod retainer.



7. Install the master cylinder.
8. Install the master cylinder mounting nuts.

Tighten
Tighten the nuts to 36 N·m (27 lb ft).

9. Install the hoses.

Tighten
Tighten the hoses to 27 N·m (20 lb ft).

10. Bleed the booster. Refer to Power Steering System Bleeding in Power Steering System.
11. Release the parking brake.

Power Brake Booster Replacement Motorhome

Notice: Power steering fluid and brake fluid cannot be mixed. If brake seals contact power steering fluid or steering seals contact brake fluid, seal damage will result.

Bleed the hydraulic booster system any time you open the system. Refer to Power Steering System Bleeding -Process or Power Steering System Bleeding -Special Conditions in Power Steering System.

Refer to Power Steering System Flushing in Power Steering System.

Refer to: Power Steering Hoses Replacement

Refer to Power Steering Pump Replacement -4.3L and 5.7L, Power Steering Pump Replacement -6.5L (Diesel), or Power Steering Pump Replacement -7.4L in Power Steering System.

1. Apply the parking brake.
2. Disconnect the hoses from the booster assembly.
3. Remove the master cylinder mounting nuts.
4. Remove the master cylinder.

Support the master cylinder.

5. Remove the brake pedal rod.



6. Remove the brake-booster-to-frame mounting nut.
7. Remove the brake-booster-to-frame mounting bolt and washer.



8. Remove the brake-booster-to-frame mounting nut.
9. Remove the brake-booster-to-frame mounting bolt and washer.



10. Remove the brake-booster-to-frame mounting nuts.
11. Remove the brake-booster-to-frame mounting bolts and washers.
12. Remove the booster assembly.

1. Install the booster assembly.



2. Install the brake-booster-to-frame mounting bolts and washers.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the brake-booster-to-frame mounting nuts.

Tighten
Leave the nuts finger tight.




4. Install the brake-booster-to-frame mounting bolt and washer.
5. Install the brake-booster-to-frame mounting nut.

Tighten
Leave the nut finger tight.




6. Install the brake-booster-to-frame mounting bolt and washer.

Important: Install the brake-booster-to-frame mounting bolt with the head on the inboard side of the vehicle.

7. Install the brake-booster-to-frame mounting nut.

Tighten
Leave the nut finger tight and tighten all of the brake-booster-to-frame mounting nuts to 36 N·m (27 lb ft).

8. Install the brake pedal rod.



9. Install the master cylinder.
10. Install the master cylinder mounting nuts.

Tighten
Tighten the master cylinder mounting nuts to 36 N·m (27 lb ft).

11. Install the hoses.

Tighten
Tighten the hoses to 27 N·m (20 lb ft).

12. Bleed the booster. Refer to Power Steering System Bleeding in Power Steering System.
13. Release the parking brake.