GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2004 🢒 Isuzu MD F-Series 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Brake Booster Replacement

Removal Procedure
  1. Block the wheels.
  2. Clean and flush the hydraulic booster system when the hydraulic pump is replaced. Metal shavings from a worn hydraulic pump contaminate the system.
  3. Disassemble the booster head. Clean the booster head. Replace all the seals and the o-ring seals.
  4. Remove and clean the pipes and hoses of all metal shavings.
  5. Tilt the cab. Refer to Cab Tilting .
  6. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch.

    7. Object Number: 220749 Size: SH
  7. Remove the master cylinder bracket.
  8. Remove the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position.

    9. Object Number: 220742 Size: SH
  9. Disconnect the hoses from the booster.

    10. Object Number: 220748 Size: SH
  10. Remove the booster pump rod nut from the lever.
  11. Remove the nuts at the booster.
  12. Remove the booster assembly.

Installation Procedure

    Object Number: 220748 Size: SH
  1. Install the booster assembly to the vehicle.

    2. 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.

  2. Install the nuts at the booster.

    3. Tighten
    Tighten the nuts to 36 N·m (27 lb ft).

  3. Install the booster pump rod to the lever.

    4. Tighten
    Tighten the nuts to 68 N·m (50 lb ft).


    Object Number: 220742 Size: SH
  4. Install the hoses to the booster.

    5. Object Number: 220749 Size: SH
  5. Install the master cylinder.
  6. Install the master cylinder bracket.

    7. Tighten
    Tighten the nuts to 45 N·m (33 lb ft).

  7. Install the electrical connectors to the electrohydraulic pump and the flow switch.
  8. Fill the hydraulic pump reservoir.
  9. Bleed the system.
  10. Lower the cab. Refer to Cab Tilting .
  11. Inspect the vehicle for the proper brake operation.
  12. Remove the wheel blocks.