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 Panel Replacement - Left Side.



2. Remove the vacuum brake booster pushrod retaining clip (1).



3. Disconnect the vacuum brake booster pushrod (1) from the brake pedal pivot.



4. Remove the vacuum brake booster pushrod bushing (1).



5. Remove the vacuum brake booster pushrod wave washer (1).



6. Remove the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.
7. Disconnect the master cylinder fluid level sensor electrical connector.
8. Remove the master cylinder nuts (1).
9. Without disconnecting the brake pipes, position aside the master cylinder and support with heavy mechanics wire or equivalent.
10. Without disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement.



11. Disconnect the vacuum brake booster check valve and hose assembly (1) and position aside.

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

12. Modify the J-22805-B Brake Booster Holder to accomodate 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)




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



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

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

16. Carefully pull the vacuum booster forward slightly and support the vacuum booster to access the booster pushrod retaining clip.



17. Disconnect the brake booster pushrod (1) from the booster by releasing the retaining clip (2).
18. Remove the vacuum brake booster from the vehicle.
19. Remove the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if necessary.

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.

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

1. Install the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if removed.
2. Position the vacuum brake booster to the vehicle.
3. Connect the brake booster pushrod (1) to the booster and engage the retaining clip (2).



4. Position the vacuum brake booster and the J-22805-B Brake Booster Holder  (1) to the bracket.
5. Rotate the vacuum booster clockwise until the locking tab (2) engages the cowl flange.

Ensure the booster locking tab fully engages in the bracket.

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



7. Install the vacuum brake booster check valve and hose assembly (1).



8. Install the master cylinder to the 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 master cylinder fluid level sensor electrical connector.
11. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement.
12. Install the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.



13. Install the vacuum brake booster pushrod wave washer (1).



14. Install the vacuum brake booster pushrod bushing (1).



15. Connect the vacuum brake booster pushrod (1) to the brake pedal pivot.



16. Install the vacuum brake booster pushrod retaining clip (1).
17. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
18. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.

Power Vacuum Brake Booster Replacement RHD

Special Tools

J-22805-B Brake Booster Holder Brake Booster Holder

1. Remove the right side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side.



2. Remove the vacuum brake booster pushrod retaining clip (1).



3. Disconnect the vacuum brake booster pushrod (1) from the brake pedal pivot.



4. Remove the vacuum brake booster pushrod bushing (1).



5. Remove the vacuum brake booster pushrod wave washer (1).



6. Remove the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.
7. Disconnect the master cylinder fluid level sensor electrical connector.
8. Remove the master cylinder nuts (1).
9. Without disconnecting the brake pipes, position aside the master cylinder and support with heavy mechanics wire or equivalent.



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

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 accomodate 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) to the vacuum brake booster and secure with the master cylinder nuts.
13. Using a flat-bladed tool, depress the locking tab (2) toward the cowl.



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

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

15. Carefully pull the vacuum booster forward slightly and support the vacuum booster to access the booster pushrod retaining clip.



16. Disconnect the brake booster pushrod (1) from the booster by releasing the retaining clip (2).
17. Remove the vacuum brake booster from the vehicle.
18. Remove the vacuum brake booster pushrod through the dust boot from inside of the vehicle, if necessary.

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.

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

1. Install the 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. Connect the brake booster pushrod (1) to the booster and engage the retaining clip (2).



4. Position the vacuum brake booster (1) to the booster bracket.



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

Ensure the booster locking tab fully engages in the bracket.

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



7. Install the vacuum brake booster check valve and hose assembly (1).



8. Install the master cylinder to the 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 master cylinder fluid level sensor electrical connector.
11. Install the cross vehicle brace, if equipped. Refer to Cross Vehicle Brace Replacement.



12. Install the vacuum brake booster pushrod wave washer (1).



13. Install the vacuum brake booster pushrod bushing (1).



14. Connect the vacuum brake booster pushrod (1) to the brake pedal pivot.



15. Install the vacuum brake booster pushrod retaining clip (1).
16. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
17. Install the right side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side.