GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the coolant surge tank. Refer to Radiator Surge Tank Replacement .

  3. Object Number: 675866  Size: SH
  4. Disconnect the electrical connector (1) from the brake fluid level sensor.

  5. Object Number: 63941  Size: SH
  6. Remove the nuts securing the master cylinder to the brake booster.
  7. Remove the master cylinder from the brake booster without disconnecting the brake pipes and position the master cylinder aside.

  8. Object Number: 63936  Size: SH
  9. Disconnect the brake booster vacuum hose from the booster check valve.
  10. Remove the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement .

  11. Object Number: 63944  Size: SH
  12. Remove the retainer, washer, brake pedal pin, and brake booster pushrod from the brake pedal.

  13. Object Number: 63943  Size: SH
  14. Remove the brake booster mounting nuts and washers from the booster studs.
  15. Important: The brake booster is retained to the cowl with push-on nuts.

  16. In order to remove the booster from the cowl, perform the following steps:
  17. • In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
    • Pull the booster straight out.
  18. Remove the brake booster and seal from the cowl.
  19. Inspect the booster seal and sealing surfaces for damage. Replace the seal if necessary.

Installation Procedure


    Object Number: 63943  Size: SH
  1. Install the seal and brake booster to the front of dash.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install brake booster mounting nuts and washers to the booster studs.
  4. Tighten
    Tighten the brake booster mounting nuts to 27 N·m (19 lb ft).


    Object Number: 63944  Size: SH
  5. Install the brake booster pushrod, brake pedal pin, washer, and retainer to the brake pedal. Verify proper engagement of the retainer to the brake pedal by rotating the retainer.
  6. Install the instrument panel lower trim panel. Refer to Driver Knee Bolster Panel Replacement .

  7. Object Number: 63936  Size: SH
  8. Connect the brake booster vacuum hose to the brake booster check valve.

  9. Object Number: 63941  Size: SH
  10. Install the master cylinder to the brake booster.
  11. Install the master cylinder mounting nuts.
  12. Tighten
    Tighten the master cylinder mounting nuts to 29 N·m (21 lb ft).


    Object Number: 675866  Size: SH
  13. Connect the electrical connector (1) to the brake fluid level sensor.
  14. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement .
  15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  16. Program the transmitters. Refer to Transmitter Programming .