Power Brake Booster Replacement Exc 3500HD

Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid.

For information on checking and adding fluid to the hydraulic booster system, refer to Fluid Level in Power Steering System.

Refer to Bleeding the Power Steering System in Power Steering System.

Refer to Flushing the Power Steering System in Power Steering System.

Refer to Power Steering Hoses in Power Steering System.

Refer to Power Steering Pump Replacement in Power Steering System.

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 negative battery cable.
2. Apply the parking brake.
3. Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly.



4. Remove the master cylinder nuts.



5. Remove the master cylinder and wiring harness bracket.
6. Remove the stoplamp switch and the pushrod.



7. Remove the booster to bulkhead nuts.
8. Remove the booster assembly.
9. Remove the gasket.

1. Install the gasket.
2. Install the booster assembly.

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.

3. Install the booster to bulkhead nuts.

Tighten
Tighten the nuts to 36 N·m (26 lb ft).

4. Install the stoplamp switch and pushrod.



5. Install the master cylinder and bracket.



6. Install the master cylinder nuts.

Tighten
Tighten the nuts to 30 N·m (20 lb ft).

7. Connect the return hose, steering gear, and inlet hoses.
8. Connect the negative battery cable.
9. Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System.

Power Brake Booster Replacement 3500HD

Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid.

For information on checking and adding fluid to the hydraulic booster system, refer to Fluid Level in Power Steering System.

Refer to Bleeding the Power Steering System in Power Steering System.

Refer to Flushing the Power Steering System in Power Steering System.

Refer to Power Steering Hoses in Power Steering System.

Refer to Power Steering Pump Replacement in Power Steering System.

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 negative battery cable.
2. Apply the parking brake.
3. Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly.



4. Remove the master cylinder nuts.



5. Remove the master cylinder (1), the wiring harness bracket (2), and the spacer (3) from the booster assembly (4).
6. Remove the stoplamp switch. Refer to Stop Lamp Switch Replacement in hydraulic brakes.



7. Remove the pushrod from the brake pedal pin.



8. Remove the booster nuts.
9. Remove the booster assembly.
10. Remove the gasket.

1. Install the gasket.
2. Install the booster assembly.

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.

3. Install the booster nuts.

Tighten
Tighten the nuts to 36 N·m (26 lb ft).




4. Install the pushrod to the brake pedal pin.
5. Install the stoplamp switch. Refer to Stop Lamp Switch Replacement in hydraulic brakes.



6. Install the spacer (3), the wiring harness bracket (2), and the master cylinder (1) to the booster assembly (4).



7. Install the master cylinder nuts.

Tighten
Tighten the nuts to 30 N·m (20 lb ft).

8. Connect the return hose, steering gear, and inlet hoses.
9. Connect the negative battery cable.
10. Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System.