Changing a Power Brake Booster and Master Brake Cylinder is relatively easy. Warning to the 05 owners, the Power Booster is a 05 only part, apparently 06 and up has a different part number.

Tools Required:
10mm Socket.
13mm Socket.
15mm Socket
3” Extension
Ratchet.
13mm Open End Wrench.
45 degree pliers.
Flat Head Screw Driver.
Torque Wrench.


Parts Required:
Brake Master Cylinder (if replacing).
Power Brake Booster (if replacing).
Brake Pedal Pin Retaining Clip (one time use only, make sure you have this, took a week to get one into my dealer)
Brake Lamp Switch.



  • Disconnect the Battery.
  • Remove Windshield Wiper Arms. There is a cover over the 15mm bolt, just slide a flat head screw driver under the cover and twist. Remove the Bolt that holds the wiper arm. The drivers side just comes off, but for the passenger side, I had to press down slightly where the hinge on the wiper arm is to relieve the pressure on the eyelet area to make it easier to remove.
  • Remove panel that is mounted at the bottom of the windshield. There are several clips that hold it in place, I just pried them up with a flat head screw driver and pulled them out with 45degree pliers. The ones with Red arrows need to be removed and the Blue just needs to be turned 90dregrees.


  • Remove all connectors (4 sensors if ESP equipped). 2 on Power Booster (1 on left and 1 on right), 2 on Master (1 on left side and 1 on bottom). (#4)
  • Disconnect Vacuum hose from Check Valve. (#5)
  • Remove the two Brake Lines from the Master Cylinder using a 13mm wrench. (#6)


  • Remove the 2 13mm Nuts that mount the Master Cylinder to Booster. I used a 3” Extension which was perfect to allow the ratchet to sit between the Master Cylinder and Fender well. (#7)
  • Remove Master Cylinder.


  • Disconnect the connector on the wiper motor. (#9)
  • Remove the 2 10mm Screws that hold the Windshield wiper assembly on the Bulkhead/Firewall. It is required to make enough room to remove the Power Boster. (#10)


Now go inside the Vehicle, under dash:

  • Remove carpet on the bottom of the dash.
  • Turn the Brake Pedal Switch 30degrees to remove. #2 in this piture


  • Remove Booster Push Rod from Brake Pedal Pin. There is a retaining clip that holds the pedal pin. (CAUTION: THIS RETAINIG CLIP NEEDS TO BE REPLACED, make sure you have a new one, they are one time use only). Use a flathead screw driver to and slide it in between the retaining clip and the brake pedal then twist. This broke the end off mine then you can just slide it out. I tried to take a picture of the clip installed but my camera just won’t do it. It is located on the left side of the brake pedal where the brake pedal is connected with the power booster. #3 in this picture



  • Remove 4 13mm bolts that mount the Power Booster to the Bulkhead/Firewall. (#12)

In the engine Bay:

  • Pull the Power Booster out and remove.

Installation.

  • Mount new pad on rear of Power Brake Booster.
  • Put Power Booster back into place.
  • Install the 4 13mm nuts that hold the unit in place and torque to 19ft lbs (25 NM).
  • Slide Booster Push Rod into Brake Pedal Pin
  • Install NEW Retaining Clip. (only goes in one way).
  • Connect Vacuum Hose onto Check Valve.
  • Connect the 2 connectors for the Power Booster.
  • Install Brake Master Cylinder.
  • Connect Brake Lines.
  • Connect the 2 connectors for the master cylinder.
  • Install Wiper Assembly.
  • Install Panel at bottom of Windshield.
  • Install Wipers.
  • Connect Battery.
  • Install new brake lamp switch.
  • You will need to adjust Brake Lamp Switch also.


  • Fill Master Cylinder with brake fluid and Bleed Brakes.
http://www.zeckhausen.com/bleeding_brakes.htm


  • ENSURE PROPER OPERATION BEFORE DRIVING.