1. Remove the brake modulator assembly (if equipped with ABS). Refer to Brake Pressure Modulator Valve Assembly Replacement in Antilock Brake System.
2. Remove the master cylinder. Refer to Master Cylinder Replacement .



3. Remove the hose clamp and the hose from the booster (1).



4. Remove the cotter pin (1) and the clevis pin (6) from the push rod clevis (5).
5. Remove the push rod clevis (5) from the brake pedal.
6. Remove the four mounting nuts (2) and the booster assembly from the bulkhead.

Tools Required

J 39567 Brake Booster Piston Rod Height Gauge

1. Adjust the booster piston rod to the master cylinder piston (3). Push the booster piston rod (2) several times in order to ensure that the reaction disc is in place.



2. Set the J 39567 on the master cylinder (1).
3. Push the J 39567 pin down until the pin touches the master cylinder piston (2).
4. Remove the J 39567 from the master cylinder (1).



5. Turn the J 39567 upside down and set it on the booster assembly (1).
6. Measure the clearance (2) between the booster piston rod and the J 39567 . Ensure that there is no clearance (0 mm, 0 in) between the booster piston rod (3) and the J 39567 .
7. If the booster piston rod length is not within specifications, adjust the length by turning the booster piston rod adjusting nut until the specification is reached.

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. Measure the push rod clevis length. Install the push rod clevis (2) so that a push rod clevis length ranging from 99.5-100.5 mm (3.92-3.96 in) is obtained.

Tighten
Tighten the push rod clevis locknut to 25 N·m (18 lb ft).

2. Apply silicone grease to the master cylinder piston.
3. Install the booster assembly to the bulkhead. Do not tighten the mounting nuts.



4. Install the push rod clevis (5) to the brake pedal. Secure the push rod clevis with a clevis pin (6) and cotter pin (1).
5. Secure the booster assembly mounting nuts.

Tighten
Tighten the booster assembly mounting nuts to 13 N·m (115 lb in).

6. Install the hose to the booster assembly. Secure the hose with a hose clamp.
7. Install the master cylinder. Refer to Master Cylinder Replacement .
8. Install the brake modulator assembly (if equipped with ABS). Refer to Brake Pressure Modulator Valve Assembly Replacement in Antilock Brake System.