GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Firebird 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure
  1. Remove the hood rear seal. Refer to Hood Rear Seal Replacement in Body Front End.
  2. Remove the left and right side windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper/Washer Systems.
  3. Remove the left side air inlet screen. Refer to Air Inlet Grille Panel Replacement in Body Front End.

    4. Object Number: 184981 Size: SH
  4. Remove the brake booster vacuum hose (8) and clamp (9) from the check valve (10).
  5. Remove the master cylinder form the brake booster. Refer to Master Cylinder Replacement .
  6. Remove the left side I/P insulator. Refer to Instrument Panel Insulator Replacement in Instrument Panel, Gauges and Console.

    7. Object Number: 184982 Size: SH
  7. Remove the brake pedal nuts (3) attaching the brake booster to the brake pedal with bracket (6).
  8. On manual transmission equipped vehicles only, loosen the clutch master cylinder nuts (5).
  9. Disconnect the brake booster pushrod (8) from the brake pedal lever pin.
    10. 9.1. From inside the vehicle, remove the brake pedal pushrod retainer (7) and pushrod washer (4).
    9.2. Tilt the entire brake booster slightly in order to work the brake booster pushrod (8) off the brake pedal pin. Do not put undue side pressure on the pushrod.
  10. Remove the power brake booster from the vehicle.

Installation Procedure
  1. Install the power brake booster onto the vehicle.

    2. Object Number: 184982 Size: SH
  2. Install the brake booster pushrod (8) to the brake pedal lever pin (1).
    3. 2.1. Tilt the entire brake booster slightly in order to work the brake booster pushrod onto the brake pedal pin.
    2.2. From inside the vehicle, install the brake pedal pushrod washer (4) and retainer (7).

    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 brake pedal nuts (3) attaching the brake booster to the brake pedal with bracket (6).

    4. Tighten
    Tighten the brake pedal nuts to 20 N·m (15 lb ft) in the following sequence:

    3.1. Inboard upper
    3.2. Outboard lower
    3.3. Outboard upper
    3.4. Inboard lower
  4. On manual transmission equipped vehicles only, install the clutch master cylinder nuts (7).

    5. Tighten
    Tighten the clutch master cylinder nuts to 27 N·m (20 lb ft).


    Object Number: 184981 Size: SH
  5. Install the master cylinder (6) onto the brake booster (1).
  6. Install the master cylinder nuts (7) attaching the master cylinder to the brake booster.

    7. Tighten
    Tighten the brake master cylinder nuts to 29 N·m (21 lb ft)

  7. Connect the vacuum hose (8) and the clamp (9) to the check valve (10).
  8. Install the left side instrument insulator. Refer to Instrument Panel Insulator Replacement in Instrument Panel, Gauges and Console.
  9. Install the left side air inlet screen. Refer to Air Inlet Grille Panel Replacement in Body front End.
  10. Instal the left and right side wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper Washer Systems.
  11. Install the hood rear seal. Refer to Hood Rear Seal Replacement in Body Front End.
  12. Bleed the brakes. Refer to Hydraulic Brake System Bleeding .