Express 1500 AWD V8-5.3L VIN T (2004)
Vacuum Brake Booster: Service and Repair
Hydraulic Brake Booster Replacement
Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions.
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.
Checking and Adding Fluid
For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid.
Bleeding the Hydraulic Booster System
Refer to Bleeding the Power Steering System in Power Steering System.
Flushing the Hydraulic Booster System
Refer to Flushing the Power Steering System in Power Steering System.
Removal Procedure
1. Apply the park brake and block the wheels.
2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine
compartment.
3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly.
4. Remove the stop lamp switch.
5. Remove the 4 booster to bulkhead nuts.
6. Remove the booster assembly.
7. Remove the gasket.
Installation Procedure
1. Install the gasket.
2. Install the booster assembly.
3. Notice:
Refer to Fastener Notice in Service Precautions.
Install the 4 booster to bulkhead nuts.
