OEM 2004 Chevrolet Aveo Brake Booster

2004 Chevrolet Aveo Brake Booster Parts and Q&A

• Q: How to replace the vacuum brake booster on 2004 Chevrolet Aveo?

  A: Before working on the vacuum Brake Booster you must detach the electrical connector from its reservoir. Due to the risk of fluid leakage you need to remove the Clutch Hose connection clip on manual transaxle vehicles and seal the hose and master cylinder. Push the master cylinder gently forward and remove its attaching nuts. Keep brake lines connected while also getting rid of the booster housing seal. Detach the vacuum hose to the booster element and remove the brake lamp switch while taking out the clip on the brake pedal spring. Start by removing the booster and its support bracket from the dash panel when all mounting nuts are taken off. To handle this assembly pull out the clip and Pushrod from the pedal bracket. To disassemble the booster unscrew its bracket nuts and then extract the parts from the booster assembly which are booster, rubber boot, retainer, pushrod, and adjustment sleeve before removing the hex nut. Check both the Pushrod and adjustment sleeve for harm and alignment before putting them onto the booster together along with the hex nut. Torque the pair of parts to 16 nm (12 ft. Lbs.). Put the Pushrod through the adjustment sleeve and put on the retaining piece but ensure the spacer shows 10 inches in measurement. Put the rubber boot on the booster and place the brackets into position before tightening the booster-support connection nuts to 12 nm (9 ft. Lbs). Secure the booster bracket system onto the dash by turning its nuts firmly to 24 nm (18 ft. Lbs. Torque). Put on the master cylinder to the booster while adding its new housing seal. Tighten the master cylinder attaching nuts to 24 nm (18 ft. Lbs.). Insert the fresh vacuum hose to the booster unit and place new hose clamps on the vacuum lines. Position the Pushrod pin into the brake pedal bracket assembly before putting on the clip and spring.