GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Corvette 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure
  1. Turn the ignition switch to the OFF position.
  2. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
  3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  4. Disconnect the brake fluid level indicator switch electrical connector.
  5. Without disconnecting the radiator surge tank inlet and outlet hoses, remove the radiator surge tank and position aside. Refer to Radiator Surge Tank Replacement.

    6. Object Number: 2141632 Size: SH
  6. Disconnect the vacuum brake booster check valve (1) from the power vacuum brake booster and position aside.

    7. Object Number: 2141633 Size: SH
  7. Remove the master cylinder nuts (1).
  8. Without disconnecting the brake pipe fittings, remove the master cylinder and position aside.

    9. Secure the master cylinder in an upright position with heavy mechanics wire or equivalent.

  9. Remove the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement.
  10. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement.
  11. Remove the telescoping steering column motor bracket and position the motor assembly to the right of the steering column. Refer to Telescope Motor Assembly Replacement.

    12. Object Number: 2141635 Size: SH
  12. Remove the brake booster pushrod clevis pin retainer (1).

    13. Object Number: 2141636 Size: SH
  13. Remove the brake booster pushrod clevis pin (1).

    14. Object Number: 2141638 Size: SH
  14. Remove the power vacuum brake booster nuts (1).

    15. Note: The power vacuum brake booster is retained to the cowl with push-on nuts during assembly.


    Object Number: 2141640 Size: SH
  15. Remove the power vacuum brake booster (1).

    16. Move the power vacuum brake booster from side-to-side to release the booster studs from the push-on nuts.

  16. Remove the power vacuum brake booster gasket (2).

    17. Inspect the gasket for damage and replace, if necessary.

Installation Procedure

    Object Number: 2141640 Size: SH
  1. Install the power vacuum brake booster (1) and the gasket (2) to the vehicle.

    2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2141638 Size: SH
  2. Install the power vacuum brake booster nuts (1) and tighten to  27 N·m (20 lb ft).

    3. Object Number: 2141636 Size: SH
  3. Install the brake booster pushrod clevis pin (1) to the brake pedal and the power vacuum brake booster pushrod.

    4. Object Number: 2141635 Size: SH
  4. Install the brake booster pushrod clevis pin retainer (1).

    5. Rotate the clevis pin retainer to ensure it is fully engaged in the clevis pin groove.

  5. Position and install the telescoping steering column motor and bracket assembly to the steering column. Refer to Telescope Motor Assembly Replacement.
  6. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement.
  7. Install the driver knee bolster panel. Refer to Driver Knee Bolster Panel Replacement.

    8. Object Number: 2141633 Size: SH
  8. Install the master cylinder to the power vacuum brake booster.
  9. Install the master cylinder nuts (1) and tighten to  18 N·m (13 lb ft).
  10. Connect the brake fluid level indicator switch electrical connector.

    11. Object Number: 2141632 Size: SH
  11. Connect the vacuum brake booster check valve (1) to the power vacuum brake booster.
  12. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement.
  13. Connect the brake fluid level indicator switch electrical connector.
  14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.