J 22805-B Power Brake Booster Holder

Caution: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the left instrument panel (IP) insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
3. Remove the retaining clip and disconnect the vacuum brake booster pushrod from the brake pedal.
4. Partially drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



5. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.
6. Relieve fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.5L.
7. Disconnect the EVAP canister purge valve pipe, the fuel feed and return pipe. Position the pipes aside.
8. Disconnect the vacuum hose and the booster check valve from the brake booster.
9. Remove the master cylinder mounting nuts and position the master cylinder to one side. Refer to Master Cylinder Replacement .
10. Remove the brake pressure modulator valve (BPMV) and the brake master cylinder from the vehicle as an assembly. It is not necessary to disconnect the master cylinder from the BPMV. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
11. Remove the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
12. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
13. Disconnect the coolant bypass hose. Position the hose aside.
14. Remove the coolant bypass pipe.
15. Attach the J 22805-B to the vacuum brake booster using the master cylinder mounting nuts.



16. Unlock the vacuum brake booster from the cowl.

Use a flat bladed tool to depress the brake booster locking tab (1) out of the cowl mounting flange while turning the booster counterclockwise with a ratchet on the J 22805-B  (2).

17. Remove the vacuum brake booster.

Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.

Important: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.

Important: Carefully push the pushrod eye through the hole so that you do not damage or dislodge the insulator boot.

1. Install the vacuum brake booster.
2. Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster engage with the mounting flanges on the cowl.




Important: Ensure that the locking tab and the flanges are in the fully engaged position.

3. Turn the vacuum brake booster clockwise with a ratchet on J 22805-B  (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
4. Remove J 22805-B  (2) from the installed vacuum brake booster
5. Install the coolant bypass pipe.
6. Reconnect the coolant bypass hose.
7. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
8. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
9. Install the vacuum hose to the vacuum brake booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
10. Install the brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
11. Install the master cylinder. Refer to Master Cylinder Replacement .
12. Install the vacuum hose and booster check valve to the brake booster.
13. Connect the EVAP canister purge valve pipe, the fuel feed and return pipe.



14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.
15. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
16. Connect the vacuum brake booster pushrod to the brake pedal and install the retaining clip.
17. Install the left IP insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.