Caution: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.

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

Tools Required

J 22805-01 Power Brake Booster Holder

1. Remove the fuel injector sight shield (3.8 Liter engine only).

Important: It is not necessary to undo brake lines from the master cylinder or (If equipped with ABS) the brake modulator.

2. (If equipped with ABS) Remove the Brake modulator. Refer to Brake Pressure Modulator Valve Replacement and remove the master cylinder. Refer to Master Cylinder Replacement .
3. Remove the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement .
4. Remove the EGR heat shield.

Notice: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.

5. Remove the brake booster pushrod from the brake pedal. Refer to Brake Pedal Replacement .



6. Remove the vacuum hose (2) from the brake booster vacuum check valve (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

7. Attach the J 22805-01 to the booster (2) using the master cylinder nuts.

Tighten
Tighten the master cylinder nuts to 25 N·m (18 lb ft).




8. Unlock the booster from the front of the dash.
9. Use a flat bladed tool (4) in order to pry the locking tab (5) on the booster out of the locking notch (3) on the mounting flange. Do this while turning the booster counterclockwise with a wrench (1) on the J 22805-01 .

Notice: Do not attempt to remove the booster until pushrod is disconnected from the brake pedal.

Important: Do not damage the insulator boot mounted on the front of the dash when pulling the pushrod eye through the hole.

10. Remove the 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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Attach the J 22805-01 to the new booster using the master cylinder nuts.

Tighten
Tighten the master cylinder nuts to 25 N·m (18 lb ft).





Important: Carefully push the pushrod (1) eye through the hole so that you do not damage or dislodge the insulator boot.

2. Place the booster on the cowl counterclockwise from the final installation position so that the locking flanges on the booster and on the mounting engage.

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

3. Turn the booster clockwise (3) with the wrench on the J 22805-01 . Do not use a screwdriver in the locking tab in order to install the booster. When the booster is correctly installed, the locking tab slides up the flange and snaps in the locking notch.
4. Connect the brake booster pushrod to the brake pedal. Refer to Brake Pedal Replacement .



5. Connect the vacuum hose (2) to the brake booster vacuum check valve (1).
6. Install the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement .
7. Install the EGR heat shield.
8. (If equipped with ABS) Install the brake modulator. Refer to Brake Pressure Modulator Valve Replacement and Install the master cylinder. Refer to Master Cylinder Replacement .
9. Install the fuel injector sight shield (3.8 Liter engine only).