How to Install a Rebuilt Brake Booster

Lead Image
  • 2-4 hours
  • Intermediate
  • 50-250
What You'll Need
Empty bucket
Turkey baster
Protective gear
Brake booster

Wear and tear, damages, and mechanical faults eventually affect the working condition of a brake booster. Depending on the extent of the problem, it can be rebuilt and/or replaced to restore the effectiveness of the braking system. Rebuilding it usually costs more than just replacing it with a new one, but if the vehicle is a classic model, then rebuilding and maintaining the original component is a better idea.

Step 1 – Remove Master Cylinder Cover

Safely position your car in a place that provides enough room to work around it easily, and put on protective work gear, including gloves and safety glasses. Then, find the master cylinder and carefully remove the cover. If there is any fluid left inside, use a turkey baster to suction it out and empty it into a bucket.

Step 2 – Disconnect Brake Lines

Use a line wrench to disconnect brake lines and plug them. Another method that can be used instead of plugging them is to tape over the ends. This prevents the fluid from dripping or pouring on other components.

Step 3 – Remove Master Cylinder

Locate the nuts on the power brake booster. Use a wrench to loosen them and carefully remove them, placing them in a safe place. Be careful not to damage the threads when removing the master cylinder.

Step 4 – Disconnect the Vacuum Line and Remove the Booster

Locate the vacuum hose and disconnect it from the booster. Get under the dashboard and locate the bolt holding the pedal to the push rod. Use a ratchet and socket to loosen the nut first, and then remove it gently using hands to avoid damaging the threads.

To remove the booster, locate the four studs that are holding it in position. Loosen and remove them and carefully release the brake booster from its location.

Step 5 – Rebuild Brake Booster

It is highly advisable to have brake boosters rebuilt in a shop. Find one that does such services. If it is possible, aim for a shop that deals with the particular model of the car. This helps to take care of small details that are inherent to any technology associated with a car’s make. It might take about 24 hours to have it rebuilt.

Step 6 – Replace Brake Booster

Position the rebuilt brake booster in place and fasten the four studs used to secure it. Carefully tighten nuts using a wrench or ratchet and socket, while taking care not to use too much force. Install the rod linkage to the brake pedal and secure it using bolts and nuts.

Mount the master cylinder again and tighten it using the two nuts, and reattach the vacuum hoses and connect hydraulic lines to the master cylinder. Make sure all components are secure before testing the braking system.