Power Vacuum Brake Booster Replacement LHD

Special Tools

J-22805-B Brake Booster Holder

1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side.
2. Without disconnecting the steering column from the intermediate shaft, lower and support the steering column. Refer to Steering Column Replacement.



3. Disconnect the brake pedal position sensor electrical connector (1).



4. Remove the power vacuum brake booster pushrod nut (1).
5. Disconnect the power vacuum brake booster pushrod from the brake pedal pivot.
6. Remove the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.
7. Disconnect the brake fluid level indicator switch electrical connector.



8. Disconnect the power vacuum brake booster check valve and hose assembly (1).



9. Remove the master cylinder nuts (1).



10. Without disconnecting the brake pipe fittings, position aside the master cylinder (1) and support with heavy mechanics wire or equivalent.
11. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
12. Without disconnecting the hoses, remove and position aside the surge tank. Refer to Radiator Surge Tank Replacement.

Note: Do not attempt to lever against the master cylinder mounting studs to remove the power vacuum brake booster.

13. Modify the J-22805-B Brake Booster Holder to accommodate the narrower span between the master cylinder mounting studs on the power vacuum brake booster:

•	Using a suitable grinding tool or metal file, elongate the mounting holes of the J-22805-B Brake Booster Holder

•	Remove approximately 6.36 mm (0.25 in) of material from the inner edges of both mounting holes

•	Remove material from the inner edges of the mounting until the span, from center to center, is approximately 80.00 mm (3.15 in)




14. Install the J-22805-B Brake Booster Holder  (1) and secure with the master cylinder nuts.
15. Using a flat-bladed tool, depress the locking tab (2) toward the cowl.

Note: Do not attempt to remove the power vacuum brake booster completely. The power vacuum brake booster pushrod retaining clip must be released prior to booster removal.




16. Rotate the J-22805-B Brake Booster Holder and power vacuum brake booster (1) counter clockwise and release the power vacuum brake booster from the bracket.



17. Carefully pull the power vacuum brake booster forward slightly and support the power vacuum booster to access the booster pushrod retaining clip.
18. Compress the power vacuum brake booster foam filter to access the power vacuum brake booster pushrod retaining clip.
19. Disconnect the power vacuum brake booster pushrod (1) from the booster by releasing the retaining clip (2).
20. Remove the power vacuum brake booster from the vehicle.
21. Remove the power vacuum brake booster pushrod through the dust boot from inside of the vehicle, if necessary.

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

Caution: 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.

1. Install the power vacuum brake booster pushrod through the dust boot from inside of the vehicle, if removed.
2. Install the vacuum brake booster to the vehicle.
3. Compress the power vacuum brake booster foam filter to access the vacuum brake booster pushrod retaining clip.



4. Connect the power vacuum brake booster pushrod (1) to the booster and engage the retaining clip (2).
5. Position the power vacuum brake booster to the booster bracket.



6. Using the J-22805-B Brake Booster Holder  (1), rotate the power vacuum brake booster clockwise until the locking tab (2) engages the booster bracket flange.

Ensure the booster locking tab fully engages in the bracket.

7. Remove the J-22805-B Brake Booster Holder from the power vacuum brake booster and discard the master cylinder nuts.



8. Install the master cylinder (1) to the power vacuum brake booster.

Caution: Refer to Fastener Caution in the Preface section.




9. Install new master cylinder nuts (1) and tighten to 25 N·m (18 lb ft).



10. Connect the power vacuum brake booster check valve and hose assembly (1).

If necessary, a small amount of denatured alcohol may be used as a lubricant for assembly. Do not use soap.

11. Connect the brake fluid level indicator switch electrical connector.
12. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
13. Install the surge tank. Refer to Radiator Surge Tank Replacement.
14. Install the cross vehicle brace, if removed. Refer to Cross Vehicle Brace Replacement.



15. Connect the power vacuum brake booster pushrod to the brake pedal pivot.
16. Install the power vacuum brake booster pushrod nut (1) and tighten to 9 N·m (80 lb in).



17. Connect the brake pedal position sensor electrical connector (1).
18. Install the steering column. Refer to Steering Column Replacement.
19. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
20. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side.

Power Vacuum Brake Booster Replacement RHD

Special Tools

J-22805-B Brake Booster Holder

1. Remove the right side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Right Side.
2. Without disconnecting the steering column from the intermediate shaft, lower and support the steering column. Refer to Steering Column Replacement.



3. Disconnect the brake pedal position sensor electrical connector (1).



4. Remove the power vacuum brake booster pushrod nut (1).
5. Disconnect the power vacuum brake booster pushrod from the brake pedal pivot.
6. Remove the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.
7. Disconnect the brake fluid level indicator switch electrical connector.



8. Remove the master cylinder nuts (1).



9. Without disconnecting the brake pipe fittings, position aside the master cylinder (1) and support with heavy mechanics wire or equivalent.



10. Disconnect the power vacuum brake booster check valve and hose assembly (1).

Note: Do not attempt to lever against the master cylinder mounting studs to remove the power vacuum brake booster.

11. Modify the J-22805-B Brake Booster Holder to accommodate the narrower span between the master cylinder mounting studs on the power vacuum brake booster:

•	Using a suitable grinding tool or metal file, elongate the mounting holes of the J-22805-B Brake Booster Holder

•	Remove approximately 6.36 mm (0.25 in) of material from the inner edges of both mounting holes

•	Remove material from the inner edges of the mounting until the span, from center to center, is approximately 80.00 mm (3.15 in)




12. Install the J-22805-B Brake Booster Holder  (1) and secure with the master cylinder nuts.
13. Using a flat-bladed tool, depress the locking tab (2) toward the cowl.

Note: Do not attempt to remove the power vacuum brake booster completely. The power vacuum brake booster pushrod retaining clip must be released prior to booster removal.




14. Rotate the J-22805-B Brake Booster Holder and power vacuum brake booster (1) counter clockwise and release the power vacuum brake booster from the bracket.



15. Carefully pull the power vacuum brake booster forward slightly and support the power vacuum booster to access the booster pushrod retaining clip.
16. Compress the power vacuum brake booster foam filter to access the power vacuum brake booster pushrod retaining clip.
17. Disconnect the power vacuum brake booster pushrod (1) from the booster by releasing the retaining clip (2).
18. Remove the power vacuum brake booster from the vehicle.
19. Remove the power vacuum brake booster pushrod through the dust boot from inside of the vehicle, if necessary.

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

Caution: 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.

1. Install the power vacuum brake booster pushrod through the dust boot from inside of the vehicle, if removed.
2. Install the vacuum brake booster to the vehicle.
3. Compress the power vacuum brake booster foam filter to access the vacuum brake booster pushrod retaining clip.



4. Connect the power vacuum brake booster pushrod (1) to the booster and engage the retaining clip (2).



5. Position the vacuum power brake booster (1) to the booster bracket.



6. Using the J-22805-B Brake Booster Holder  (1), rotate the power vacuum brake booster clockwise until the locking tab (2) engages the booster bracket flange.

Ensure the booster locking tab fully engages in the bracket.

7. Remove the J-22805-B Brake Booster Holder from the power vacuum brake booster and discard the master cylinder nuts.



8. Connect the power vacuum brake booster check valve and hose assembly (1).

If necessary, a small amount of denatured alcohol may be used as a lubricant for assembly. Do not use soap.




9. Install the master cylinder (1) to the power vacuum brake booster.

Caution: Refer to Fastener Caution in the Preface section.




10. Install new master cylinder nuts (1) and tighten to 25 N·m (18 lb ft).
11. Connect the brake fluid level indicator switch electrical connector.
12. Install the cross vehicle brace, if removed. Refer to Cross Vehicle Brace Replacement.



13. Connect the power vacuum brake booster pushrod to the brake pedal pivot.
14. Install the power vacuum brake booster pushrod nut (1) and tighten to 9 N·m (80 lb in).



15. Connect the brake pedal position sensor electrical connector (1).
16. Install the steering column. Refer to Steering Column Replacement.
17. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
18. Install the right side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Right Side.