Tools Required

J 39567 Booster Push Rod Gauge

1. Remove the master cylinder (5). Refer to Master Cylinder Replacement .
2. If the vehicle is equipped with an Antilock Brakes System (ABS), remove the brake pressure modulator valve assembly and bracket (3). Refer to Brake Pressure Modulator Valve Assembly Replacement .



3. Remove the hose clamp and the hose (10) from the booster (9).
4. Remove the brake pedal return spring (6).
5. Remove the following components from the push rod clevis (3) :

•	The cotter pin (4)

•	The clevis pin (1)

•	The wave washer (2)

6. Remove the following components from the bulkhead:

•	The four mounting nuts (7,8,12,13)

•	The booster assembly (9)

•	The gasket (11)

•	The clevis (3)

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. Install the following components to the bulkhead:

•	A new gasket (11) between the booster assembly (9) and the bulkhead

•	The booster assembly (9)

•	Secure the four booster assembly mounting nuts (7,8,12,13).

Tighten
Tighten the booster assembly mounting nuts to 13 N·m (108 lb in).

2. Install the clevis (3) to the operating rod.
3. Install the following components to the clevis (3) :

•	The wave washer (2)

•	The clevis pin (1)

•	The cotter pin (4)

4. Install the brake pedal return spring (6).



5. If the vehicle is equipped with ABS, install the following components to the booster assembly (5) :

5.1.	The gasket (2)

5.2.	The bracket for the brake pressure modulator valve assembly (3)

5.3.	Three nuts. Tighten the nuts by hand.

6. Install a new gasket on the master cylinder.



7. Place the J 39567 on the gasket.
8. Lower the J 39567 pin down until the pin touches the master cylinder piston (2).
9. Remove the J 39567 from the master cylinder.



10. Turn the J 39567 upside down.
11. If the vehicle is equipped with ABS, place the J 39567 on the bracket for the brake pressure modulator valve assembly.
12. If the vehicle is not equipped with ABS, place the J 39567 on the booster assembly (1).
13. Measure the clearance (2) between the booster piston rod (3) and the J 39567 . Ensure that the clearance is 0 mm (0 in).



14. If the booster piston rod length is not within specifications, complete the following procedure:

14.1.

Ask an assistant to push the booster piston rod out by pressing the brake pedal.

14.2.

Turn the booster piston rod until the booster piston rod slightly touches the pin head.




15. If the vehicle is equipped with ABS, install the brake pressure modulator valve assembly (3). Refer to Brake Pressure Modulator Valve Assembly Replacement .
16. Install the master cylinder (5). Refer to Master Cylinder Replacement .
17. Torque the three master cylinder nuts.

Tighten
Tighten the three nuts to 13 N·m (108 lb in).

18. Install the hose to the booster assembly (1).

Secure the hose with the hose clamp.

19. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .
20. Inspect for leaks.
21. Adjust the brake pedal travel. Refer to Brake Pedal Travel .



22. Tighten the clevis lock nut (5).

Tighten
Tighten the nut to 26 N·m (19 lb ft).

23. Inspect the brake pedal free play. Refer to Brake Pedal Travel .
24. Inspect the brake pedal reserve distance. Refer to Brake Pedal Travel .
25. Inspect booster assembly. Refer to Vacuum Booster Diagnosis .