Chevrolet 96060621 Hydraulic Power Brake Booster Assembly

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To operate and check the power brake booster, start by depressing the brake pedal multiple times with the engine off to ensure there is no change in the pedal reserve distance. Then, depress the pedal and start the engine, noting if the pedal goes down slightly, indicating normal operation. For the airtightness check, start the engine and turn it off after a minute or two. Slowly depress the brake pedal several times, observing if the pedal goes down farther initially but gradually rises after subsequent depressions, indicating an airtight booster. Additionally, depress the brake pedal while the engine is running and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight. When it comes to removal, it is advised not to disassemble the power brake booster as it requires special tools. Instead, replace a defective booster unit with a new or rebuilt one. To remove the booster, first remove the brake master cylinder. Locate the pushrod clevis connecting the booster to the brake pedal and remove the clevis pin retaining clip. Disconnect the clevis locknut and the hose leading from the engine to the booster. Remove the four nuts and washers holding the brake booster to the firewall, then slide the booster straight out from the firewall and remove it from the engine compartment. For installation, follow the reverse procedures of removal, ensuring the clevis locknut and booster mounting nuts are tightened. If replacing the power booster unit, check the clevis rod length and the clearance between the master cylinder piston and the pushrod in the vacuum booster. Adjust the length of the booster pushrod using the adjusting screw on the end of the power booster pushrod until the clearance is within the specified limit.