GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Corvette 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 70094 Size: SH
  1. Remove the washer solvent container retaining nuts.
  2. Lift the washer solvent container from the left wheelhouse.
  3. Disconnect the electrical connections and the washer hose from the container.
  4. Plug the washer pump outlet.

    5. Object Number: 63958 Size: SH
  5. Disconnect the electrical connector from the brake fluid level switch.

    6. Object Number: 63961 Size: SH
  6. Remove the brake pipes from the master cylinder.

    7. Object Number: 63941 Size: SH
  7. Remove the nuts securing the master cylinder to the brake booster.
  8. Remove the master cylinder from the brake booster.

    9. Object Number: 63936 Size: SH
  9. Disconnect the brake booster vacuum check valve hose from the booster.
  10. Remove the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement in Instrument Panel, Gauges and Console.

    11. Object Number: 63944 Size: SH
  11. Remove the input push rod retaining clip and pin from the brake pedal.

    12. Object Number: 425435 Size: SH
  12. Remove the screw (3) from the telescoping column motor mounting bracket (5), if equipped.
  13. Position the motor assembly to the right of the steering column.

    14. Object Number: 63943 Size: SH
  14. Remove the brake booster mounting nuts and washers from the studs.
  15. Remove the brake booster and seal from the front of dash.
  16. Inspect the booster seal and sealing surfaces for damage. Replace if necessary.

Installation Procedure
  1. Lubricate all friction parts with Delco Brake Lube (GM P/N 12377969), or equivalent.

    2. Object Number: 63943 Size: SH
  2. Install the seal and brake booster to the front of dash.

    3. 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 brake booster mounting nuts and washers on to the studs.

    4. Tighten
    Tighten the brake booster mounting nuts to 27 N·m (19 lb ft).


    Object Number: 63944 Size: SH
  4. Lubricate the input push rod pin with Delco Brake Lube (GM P/N 12377969).
  5. Install the brake booster pushrod, brake pedal pin, washer, and retainer to the brake pedal. Verify proper engagement of the retainer to the brake pedal by rotating the retainer.

    6. Object Number: 425435 Size: SH
  6. Reposition the telescoping column motor assembly to the steering column, if equipped.
  7. Install the screw (3) to the motor mounting bracket (5).

    8. Tighten
    Tighten the screw to 7 N·m (62 lb in)

  8. Install the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement in Instrument Panel, Gauges and Console.

    9. Object Number: 63936 Size: SH
  9. Connect the brake booster vacuum check valve hose to the brake booster.

    10. Object Number: 63941 Size: SH
  10. Install the master cylinder to the brake booster.
  11. Install the master cylinder retaining nuts.

    12. Tighten
    Tighten the master cylinder retaining nuts to 29 N·m (21 lb ft).


    Object Number: 63961 Size: SH
  12. Install the brake pipes to the master cylinder.

    13. Tighten
    Tighten the brake pipe tube nuts to the master cylinder to 24 N·m (17 lb ft).


    Object Number: 63958 Size: SH
  13. Connect the electrical connector to the brake fluid level switch.

    14. Object Number: 70094 Size: SH
  14. Connect the electrical connector and the washer hose to the washer solvent container.
  15. Install washer solvent container to the wheelhouse.
  16. Install the washer solvent container retaining nuts.

    17. Tighten
    Tighten the washer solvent container nuts to 7.5 N·m (66 lb in).

  17. Bleed brake system as necessary. Refer to Hydraulic Brake System Bleeding .