Power Vacuum Brake Booster Replacement 3.9L

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
2. Disconnect the electrical connector from the exhaust gas recirculation (EGR) valve (1).
3. Disconnect the engine harness clips (3).
4. Position the harness to the side.



5. Disconnect the brake fluid level indicator switch electrical connector (1).



6. Remove the master cylinder nuts.
7. Remove the master cylinder.

Position the master cylinder aside and support with heavy mechanics wire or equivalent.




8. Disconnect the power vacuum brake booster check valve and hose (2).
9. Remove the left knee bolster. Refer to Driver Knee Bolster Replacement.
10. Remove the steering column support mounting bolts. Refer to Steering Column Replacement.
11. Lower the steering column and support with heavy mechanics wire.
12. Disconnect the brake pedal position sensor electrical connector.



13. Remove the bolt and the power vacuum brake booster pushrod retainer clip (2).
14. Remove the vacuum brake booster pushrod spacer (3).



15. Remove the power vacuum brake booster nuts (1).



16. Remove the power vacuum brake booster.

Note: Do not reuse the power vacuum brake booster gasket if damaged.

17. Remove the power vacuum brake booster gasket.

Inspect the power vacuum brake booster for damage and replace, if necessary.

1. Install the power vacuum brake booster gasket.
2. Install the power vacuum brake booster.



3. Install the power vacuum brake booster pushrod to the brake pedal.
4. Install the spacer (3).
5. Install the retaining clip (2).

Caution: Refer to Fastener Caution in the Preface section.

6. Install the power vacuum brake booster pushrod retaining clip bolt and tighten to  7 N·m (62 lb in)



7. Install the power vacuum brake booster nuts (1)  30 N·m (22 lb ft).
8. Connect the brake pedal position sensor electrical connector.



9. Install the master cylinder. Refer to Master Cylinder Replacement.
10. Install the steering column. Refer to Steering Column Replacement.
11. Install the knee bolster panel. Refer to Driver Knee Bolster Replacement.



12. Install the power vacuum brake booster check valve and hose (2).



13. Install the brake fluid level indicator switch electrical connector (1).



14. Position the engine wiring harness (2).
15. Connect the electrical connector for the EGR valve (1).
16. Connect the engine harness clips (3).
17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.
18. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.

Power Vacuum Brake Booster Replacement 4.6L

1. Place the vehicle on a flat surface.
2. Block the front wheels.
3. Apply the parking brake.
4. To allow access for the removal of the vacuum brake booster, position the gearshift lever into the lowest gear.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
6. Disconnect the fuel vapor lines in front of the brake booster.

•	For the lines that have the plastic connectors, refer to Plastic Collar Quick Connect Fitting Service.

•	For the lines that have the metal connectors, refer to Metal Collar Quick Connect Fitting Service.




7. Remove the master cylinder nuts (3).

Note: Do not disconnect the brake pipes from the master cylinder.

8. Disconnect the master cylinder (1) from the brake booster (2) and position forward.
9. Disconnect the shift control cable from the shaft lever pin and position it out of the way. Refer to Automatic Transmission Range Selector Cable Replacement - Console.



10. Disconnect the vacuum check valve (2) from the vacuum booster.
11. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
12. Remove the left knee bolster. Refer to Driver Knee Bolster Replacement.
13. To access the left lower brake pedal to vacuum brake booster mounting nut, remove the steering column mounting nuts. Refer to Steering Column Replacement.
14. Lower the steering column and support with heavy mechanics wire or equivalent.



15. Remove the power vacuum brake booster pushrod retaining clip (2) from the brake pedal.
16. Remove the spacer (3).
17. Disconnect the power vacuum brake booster pushrod from the brake pedal.



18. Remove the power vacuum brake booster nuts (1).
19. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.



20. Support the front frame with jack stands.
21. Loosen the left side frame bolts. Refer to Front Frame Replacement.
22. Lower the left side frame 51-76 mm (2-3 in) to gain clearance to remove the brake booster. Refer to Front Frame Replacement.



23. Remove the power vacuum brake booster from the vehicle.

Note: Do not reuse the power vacuum brake booster gasket if damaged.

24. Remove the power vacuum brake booster gasket.

Inspect the power vacuum brake booster gasket and replace, if necessary.

1. Install the power vacuum brake booster gasket to the booster.
2. Install the power vacuum brake booster to the vehicle.
3. Install the front frame. Refer to Front Frame Replacement.
4. Lower the vehicle.

Caution: Refer to Fastener Caution in the Preface section.




5. Install the power vacuum brake booster nuts (1) and tighten to  30 N·m (22 lb ft).



6. Apply a small amount of silicone brake lubricant to the brake pedal pivot.
7. Connect the power vacuum brake booster pushrod to the brake pedal.
8. Install the spacer (3) to the brake pedal.
9. Install the power vacuum brake booster pushrod retainer clip (2) to the brake pedal.
10. Install the power vacuum brake booster pushrod retaining clip bolt and tighten to  7 N·m (62 lb in).
11. Install the steering column. Refer to Steering Column Replacement.
12. Install the left knee bolster. Refer to Driver Knee Bolster Replacement.
13. Install the left insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.



14. Install the shift control cable to the shift cable bracket. Refer to Automatic Transmission Range Selector Cable Replacement - Console.
15. Position the gearshift lever into park.



16. Install the power vacuum brake booster check valve (2) to the brake booster.
17. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement.
18. Connect the fuel vapor lines in front of the brake booster.

•	For the lines that have the plastic connectors, refer to Plastic Collar Quick Connect Fitting Service.

•	For the lines that have the metal connectors, refer to Metal Collar Quick Connect Fitting Service.