Brake booster removal help....
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Joined: Jun 2006
Posts: 304
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From: Lancaster, tx
Subscribing. I looked at mine a while back and it looked to be a ***** of a job at first glance. IIRC I did note that the booster unbolts from inside the car. Just fun, fun, fun.
My GM service manual doesn't show the instructions to replace the brake booster in a 3rd gen, but it has them for the 4th gen. I don't know if they are similar for this repair but here's the instructions if it might help.
Power Vacuum Brake Booster Replacement
Removal Procedure
Remove the hood rear seal. Refer to Hood Rear Seal Replacement in Body Front End.
Remove the left side air inlet screen. Refer to Air Inlet Grille Panel Replacement in Body Front End.
Remove the brake booster vacuum hose (8) and clamp (9) from the check valve (10).
Remove the master cylinder form the brake booster. Refer to Master Cylinder Replacement .
Remove the left side I/P insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
Remove the brake pedal nuts (3) attaching the brake booster to the brake pedal with bracket (6).
On manual transmission equipped vehicles only, loosen the clutch master cylinder nuts (5).
Disconnect the brake booster pushrod (8) from the brake pedal lever pin.
8.1. From inside the vehicle, remove the brake pedal pushrod retainer (7) and pushrod washer (4).
8.2. 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.
Remove the power brake booster from the vehicle.
Power Vacuum Brake Booster Replacement
Removal Procedure
Remove the hood rear seal. Refer to Hood Rear Seal Replacement in Body Front End.
Remove the left side air inlet screen. Refer to Air Inlet Grille Panel Replacement in Body Front End.
Remove the brake booster vacuum hose (8) and clamp (9) from the check valve (10).
Remove the master cylinder form the brake booster. Refer to Master Cylinder Replacement .
Remove the left side I/P insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
Remove the brake pedal nuts (3) attaching the brake booster to the brake pedal with bracket (6).
On manual transmission equipped vehicles only, loosen the clutch master cylinder nuts (5).
Disconnect the brake booster pushrod (8) from the brake pedal lever pin.
8.1. From inside the vehicle, remove the brake pedal pushrod retainer (7) and pushrod washer (4).
8.2. 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.
Remove the power brake booster from the vehicle.
^ lots of unnecessary steps.
Unbolt the master cylinder and swing it to the driver side.
Pulling the left valve cover allows much more room to get the booster out (optional but worth the trouble).
Disconnect the hose.
Remove the plastic panel under the dash.
Remove the retainer clip holding the rod on the pedal.
Remove the 4 PITA to reach nuts under the dash, holding the booster to the firewall.
Fish the booster out from under the hood.
Unbolt the master cylinder and swing it to the driver side.
Pulling the left valve cover allows much more room to get the booster out (optional but worth the trouble).
Disconnect the hose.
Remove the plastic panel under the dash.
Remove the retainer clip holding the rod on the pedal.
Remove the 4 PITA to reach nuts under the dash, holding the booster to the firewall.
Fish the booster out from under the hood.
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I had the best results by using a wobbly extension, deep well socket and a few different length/combination of extensions that put the socket wrench about 2' away from the bolts. It's a bit of a pain, but can be done if patient. Best way to get the nuts back in is to put them on the socket to thread them on. IIRC the upper two were the worst to reach.
The details are staggeringly craptastic!
^ lots of unnecessary steps.
Unbolt the master cylinder and swing it to the driver side.
Pulling the left valve cover allows much more room to get the booster out (optional but worth the trouble).
Disconnect the hose.
Remove the plastic panel under the dash.
Remove the retainer clip holding the rod on the pedal.
Remove the 4 PITA to reach nuts under the dash, holding the booster to the firewall.
Fish the booster out from under the hood.
Unbolt the master cylinder and swing it to the driver side.
Pulling the left valve cover allows much more room to get the booster out (optional but worth the trouble).
Disconnect the hose.
Remove the plastic panel under the dash.
Remove the retainer clip holding the rod on the pedal.
Remove the 4 PITA to reach nuts under the dash, holding the booster to the firewall.
Fish the booster out from under the hood.
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