GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

  1. Apply the park brake.
  2. Deplete the vacuum reserve in the vacuum booster by applying the brake pedal 3 times or until the brake pedal becomes firm.

  3. Object Number: 1704907  Size: SH
  4. Remove the electrical connectors for the DOD sensor (1) and the active booster connector (2).
  5. Remove the vacuum hose from the check valve (3).
  6. Remove the 2 master cylinder nuts.
  7. Important: 

       • It is not necessary to disconnect the brake pipes from the master cylinder.
       • Ensure the O-ring vacuum seal is on the master cylinder after removal.

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

  9. Object Number: 1892248  Size: SH
  10. Remove the brake booster pushrod retainer bolt (1).

  11. Object Number: 1892250  Size: SH
  12. Remove the brake booster pushrod retainer (1).

  13. Object Number: 1892252  Size: SH
  14. Remove the stoplamp switch (1).
  15. Disconnect the brake booster pushrod from the brake pedal pivot pin.

  16. Object Number: 1892257  Size: SH
  17. Remove the brake booster nuts (1).
  18. Remove the power vacuum brake booster.
  19. Remove and discard the brake booster gasket.

Installation Procedure


    Object Number: 1892257  Size: SH
  1. Install a new brake booster gasket.
  2. Important: An assistant may be necessary to hold the brake booster in place while installing the nuts.

  3. Install the power vacuum brake booster to the vehicle.
  4. Notice: Refer to Fastener Notice in the Preface section.

    Important: Tighten the upper right brake booster nut first.

  5. Install the brake booster nuts (1).
  6. Tighten
    Tighten the nuts to  33 N·m (24 lb ft).


    Object Number: 1892252  Size: SH
  7. Connect the brake booster pushrod to the brake pedal pivot pin.
  8. Install the stoplamp switch (1).

  9. Object Number: 1892250  Size: SH
  10. Install the brake booster pushrod retainer (1).

  11. Object Number: 1892248  Size: SH
  12. Install the brake booster pushrod retainer bolt (1).
  13. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1704907  Size: SH
  14. Install the vacuum hose to the check valve (3).
  15. Connect the electrical connectors to the DOD sensor (1)  and the active booster connector (2).
  16. Install the master cylinder.
  17. Install the 2 master cylinder nuts.
  18. Tighten
    Tighten the nuts to 33 N·m (24 lb ft).