OEM 2002 Chevrolet Prizm Brake Booster

2002 Chevrolet Prizm Brake Booster Parts Questions & Experts Answers

• Q: How to replace the vacuum brake booster on 2002 Chevrolet Prizm?

  A: Start your replacement work by obtaining J 39567 Booster Push Rod Gauge. Drain the master cylinder before handling it. Take out ABS systems' brake pressure modulator valve assembly and also prepare to remove its bracket. Take off the brake pedal return spring and then the hose clamp along with its hose from the booster. Next take out the four bolts 7, 8, 12, 13 as well as the booster assembly , gasket , clevis , and push rod clevis from the bulkhead. Install the booster assembly through bulkhead using new gasket first. Secure it with four nuts 7, 8, 12, 13 and tighten them to 13 Nm (108 inch lbs.). Attach the clevis to the operating rod. Fasten the brake pedal return spring after putting the wave washer , clevis pin , and cotter pin on the clevis assembly. With ABS equipped vehicles you must install the gasket as well as the bracket for the brake pressure modulator valve assembly before adding the three nuts but do not torque them. Place the Booster Push Rod Gauge (J 39567) on the new gasket of the master cylinder and lower the pin slowly until it contacts the master cylinder piston. Disconnect the gauge. Place the booster gauge upside down on its designated position either over the brake pressure modulator valve assembly or on the booster assembly . Check the booster piston rod space alongside the gauge to show 0 mm (0 inch) clearance. To correct a wrong booster piston rod length, let an assistant enhance booster out by stepping on the brake pedal while you rotate the rod until it nearly contacts the pin end. Install brake pressure modulator valve assembly first for ABS models before putting on the master cylinder and torque all three master cylinder nuts to 13 Nm. After joining the hose to the booster assembly apply the hose clamp and proceed with brake system bleeding then check for leaks before setting brake pedal position then torque the clevis lock nut to 26 Nm (19 ft. lbs.).