Power Vacuum Brake Booster Replacement LHD

J 22805-B Brake Booster Holder

1. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel Gages, and Console.
2. Remove the vacuum brake booster push rod retaining clip (4).
3. Remove the vacuum brake booster pushrod (3) from the brake pedal.

Important: It is not necessary to disconnect the brake pipes from the master cylinder.

4. Remove the master cylinder from the vacuum brake booster and position the master cylinder aside. Refer to Master Cylinder Replacement .
5. Remove the air inlet grille panel, to access the vacuum brake booster locking tab. Refer to Air Inlet Grille Panel Replacement in Body Front End.

Important: It is not necessary to drain the coolant or disconnect the surge tank outlet hose from the surge tank.

6. Disconnect the surge tank inlet hose and position out of the way. Refer to Radiator Surge Tank Replacement in Engine Cooling.
7. Remove the coolant surge tank bolts and position the coolant surge tank out of the way. Refer to Radiator Surge Tank Replacement in Engine Cooling.
8. Connect the surge tank inlet hose to prevent coolant loss.
9. Disconnect the vacuum brake booster check valve from the vacuum brake booster and position out of the way.
10. Attach the J 22805-B to the vacuum brake booster using the master cylinder mounting nuts.



11. Unlock the vacuum brake booster from the front of the cowl.

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

12. Carefully remove the vacuum brake booster from the cowl mounting flange.
13. Support the vacuum brake booster.



14. Carefully push the vacuum brake booster foam filter (1) in enough to access the vacuum brake booster retaining clip (2).
15. Carefully lift the longer leg of the retaining clip (2) upward.
16. Carefully remove the pushrod (3) from 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.

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

1. Carefully install the vacuum brake booster to the vacuum brake booster pushrod (3).

Important:  Ensure that the long leg of the retainer clip is in the machined groove of the pushrod (3).

2. Carefully push the vacuum brake booster on to the pushrod until the long leg of the retaining clip seats into the machined groove of the pushrod.
3. Install the vacuum brake booster through the dust boot on the cowl.
4. Position the vacuum brake booster on the cowl counter clockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.

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




5. Turn the vacuum brake booster clockwise with a ratchet on the 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.
6. Remove the J 22805-B  (2) from the installed vacuum brake booster.
7. Reposition and connect the vacuum hose and check valve assembly to the booster.
8. Remove the surge tank inlet hose from the surge tank.
9. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
10. Install the surge tank inlet hose. Refer to Radiator Surge Tank Replacement in Engine Cooling.
11. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End.
12. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement .



13. Install the vacuum brake booster pushrod (3) to the brake pedal.
14. Install the vacuum brake booster push rod retaining clip (4) to the brake pedal.
15. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel Gages, and Console.

Power Vacuum Brake Booster Replacement RHD

J 22805-B Brake Booster Holder

1. Remove the left closeout/insulator. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel Gages, and Console.
2. Remove the vacuum brake booster pushrod retaining clip (4).
3. Remove the vacuum brake booster pushrod (3) from the brake pedal assembly.

Important: It is not necessary to disconnect the brake pipes from the master cylinder.

4. Remove the master cylinder from the vacuum brake booster and position the master cylinder aside. Refer to Master Cylinder Replacement .
5. Remove the air inlet grille panel, to gain access to the vacuum brake booster locking tab. Refer to Air Inlet Grille Panel Replacement in Body Front End.

Important: It is not necessary to drain the coolant or disconnect the surge tank outlet hose from the coolant surge tank.

6. Remove the coolant surge tank inlet hose from the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
7. Remove the coolant surge tank bolts and position the coolant surge tank out of the way. Refer to Radiator Surge Tank Replacement in Engine Cooling.
8. Install the coolant surge tank inlet hose to the coolant surge tank to prevent coolant loss.
9. Disconnect the vacuum brake booster check valve from the vacuum brake booster and position out of the way.
10. Attach the J 22805-B to the vacuum brake booster using the master cylinder retaining nuts.



11. Unlock the booster from the front of the cowl.

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

12. Carefully remove the vacuum brake booster from the cowl mounting flange.
13. Support the vacuum brake booster.



14. Carefully push the vacuum brake booster foam filter (1) in enough to access the vacuum brake booster retaining clip (2).
15. Carefully lift the longer leg of the retaining clip (2) upward.
16. Carefully remove the vacuum brake booster pushrod (3) from 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.

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

1. Carefully install the vacuum brake booster to the vacuum brake booster pushrod (3).

Important:  Ensure that the long leg of the retainer clip is in the machined groove of the pushrod (3).

2. Carefully push the vacuum brake booster pushrod on to the vacuum brake booster until the long leg of the retaining clip seats into the machined groove of the pushrod.
3. Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.

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




4. Turn the vacuum brake booster clockwise with a ratchet on the 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.
5. Remove the J 22805-B  (2) from the installed vacuum brake booster.
6. Reposition and connect the vacuum hose and check valve assembly to the vacuum brake booster.
7. Remove the coolant surge tank inlet hose from the coolant surge tank.
8. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
9. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End.
10. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement .



11. Install the vacuum brake booster pushrod (3) to the brake pedal assembly.
12. Install the vacuum brake booster pushrod retaining clip (4).
13. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel Gages, and Console.