GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Chevrolet C-Series Medium Duty Truck B7 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Brake Booster Replacement

Flushing the Hydraulic Booster System

Flush the hydraulic booster system when you discover the following contaminants in the system:

    • Dirt
    • Sludge
    • Water

Flushing involves running clean power steering fluid through the system until the draining fluid appears the same as the clean fluid. Contaminated fluid in the booster system can cause rubber parts to deteriorate.

    • Clean and flush the hydraulic booster system whenever you replace the hydraulic pump. Metal shavings from a worn hydraulic pump often contaminate the system.
    • Disassemble and clean the booster head.
    • Replace all seals and O-ring seals.
    • Remove pipes and hoses and blow clean of all metal shavings.

Removal Procedure

    Object Number: 208943 Size: SH
  1. Block the wheels.
  2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch.
  3. Remove the master cylinder. Refer to Master Cylinder Replacement .

    4. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position.

  4. Disconnect the hoses from the booster. Use a suitable container in order to catch the fluid.

    5. Discard the old fluid.

  5. Cover or plug the hoses.

    6. Object Number: 208860 Size: SH
  6. Remove the following components from the brake pedal:
    7. • The retainer
    • The washer
    • The pushrod

    Object Number: 208943 Size: SH
  7. Remove the nuts from the inside of the vehicle.
  8. Remove the nuts at the booster.
  9. Remove the booster assembly.

Installation Procedure

    Object Number: 208943 Size: SH
  1. Install the booster assembly.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the nuts at the booster.

    3. Tighten
    Tighten the nuts to 36 N·m (27 lb ft).

  3. Install the nuts inside the vehicle.

    4. Tighten
    Tighten the nuts to 36 N·m (27 lb ft).


    Object Number: 208860 Size: SH
  4. Install the following components to the brake pedal:
    5. • The pushrod
    • The washer
    • The retainer
  5. Install the hoses.
  6. Install the master cylinder. Refer to Master Cylinder Replacement .
  7. Connect the electrical connectors to the electrohydraulic pump and the flow switch.
  8. Fill the power steering reservoir. Refer to Checking and Adding Power Steering Fluid .
  9. Bleed the power steering system. Refer to Power Steering System Bleeding in Power Steering Systems.
  10. Inspect for proper brake operation.
  11. Remove the wheel blocks.