Brake booster removal/install

[tech_dog]

Undo the driver side motor mount and jack up on the engine (with a block of wood to protect the pan) raising it a bit. You can even leave the nut on so you don't have to realign the stud with the hole in the frame mount.

The booster will come right out.

You will be shocked how easy it is once you do this.

How far did you loosen the motor mount nut, and how far did you have to jack up the motor? I'll give this a shot for installing the new booster, as there's just no way my 94 has room as it is. I'll be nervous jacking up the motor, waiting for the sound or breaking metal.

For the removal, I finally took a sawzall to one of the booster studs to get it out, as I'm pretty sure the 30 year old original isn't working and I've already bought the replacement. I figured if nothing else it would make it easier to remove the lower manifold before putting the new booster back in.

Thanks.

 

[Malleus]

I'm using the booster R&R as an excuse to replace everything on the driver's side of the engine compartment, and clean the intakes and throttle body. At 29 years, it'a time to do some PM. 30 years tromorrow (mine's a Jan '95).

 

[CharlieS]

How far did you loosen the motor mount nut, and how far did you have to jack up the motor? I'll give this a shot for installing the new booster, as there's just no way my 94 has room as it is. I'll be nervous jacking up the motor, waiting for the sound or breaking metal.

For the removal, I finally took a sawzall to one of the booster studs to get it out, as I'm pretty sure the 30 year old original isn't working and I've already bought the replacement. I figured if nothing else it would make it easier to remove the lower manifold before putting the new booster back in.

Thanks.

You don't need to lift it far. Back the nut most of the way off and then jack it up. You'll be surprised how much of a difference it will make.

 

[tech_dog]

You don't need to lift it far. Back the nut most of the way off and then jack it up. You'll be surprised how much of a difference it will make.

I don't think I'll be surprised. It looked like the stud just needed a few more millimeters, and I was fairly hard on it. There's no way I want to put my brand new booster through that abuse, even if I could beat it into place. I don't want to damage the bellows, scratch it up, etc.

Maybe my 30 year old motor mounts have compressed more than others. I keep watching videos of what other people have done, and mine just won't go there.

 

[musthave]

If you are encountering issues with how the booster pulls back into the intake, put a piece of 2X2 between the booster and the intake, give it one good shove and it will pop right out. Tolerances! The booster goes on in a rectangular fashion, so line it up a bit before getting anything through the firewall. 2nd Person works well, or a string on the pedal to pull it up so that it connects right to the rod when ready.

 

[tech_dog]

I loosened up the engine mounting bolts, both sides, and jacked the engine up just a few millimeters. That's all I needed and the new booster slid right in.