How To Remove Brake Booster Pushrod

The sensation of a soft, spongy brake pedal when you press down to slow your vehicle is never a good sign. It likely indicates an issue with your brake booster or related components. Don’t panic – with some mechanical know-how and the right tools, you can diagnose and fix a failing brake booster pushrod yourself.

This step-by-step guide will walk you through the entire brake booster pushrod removal and replacement process, empowering you to restore firm, responsive braking and get confidently back on the road.

Here’s a quick step-by-step guide:

1. Park your car on level ground and disconnect the battery to disable electrical systems.
2. Locate the brake booster on the firewall and detach the vacuum hose with pliers.
3. Remove mounting bolts securing booster and master cylinder and separate them.
4. Use a flare nut wrench to disconnect brake lines from master cylinder.
5. Take out pushrod retaining clip or threaded fastener to release rod.
6. Pull the pushrod out of the brake booster housing without bending.
7. Inspect pushrod and replace if damaged before reinstalling the reversed steps.
8. Properly bleed the brakes to remove air bubbles afterwards.
9. Test brake operation for proper functioning before driving.

Understanding What the Brake Booster Pushrod Does

Before we dig into the removal process, it helps to understand exactly what the brake booster pushrod does. Essentially, it is a connecting rod that transmits pressure from the brake pedal to the brake master cylinder, which controls fluid pressure to the brake calipers. Here’s a quick rundown:

  1. You press the brake pedal down with your foot.
  2. The attached pushrod moves inward into the brake booster.
  3. The inward movement triggers a vacuum-powered reaction that multiplies your pedal pressure.
  4. This intensified force is transmitted through the pushrod to the master cylinder.
  5. The master cylinder pressurizes the brake fluid lines.
  6. Pressurized fluid flows to the brake calipers, slowing your vehicle.

Over months and years of use, that critical pushrod can wear out or become damaged, causing braking problems. Catching issues early and replacing the pushrod prevents more serious safety hazards and keeps you and your passengers secure.

Gather the Proper Tools and Supplies

Before wrenching around under your vehicle’s hood, assemble a toolkit containing every item needed for smooth pushrod removal and installation:

  • Socket wrench set with different head sizes
  • Combination wrenches
  • Torque wrench
  • Screwdrivers – both Phillips and flathead
  • Pliers – standard and needle-nose
  • Flare nut wrenches
  • Brake fluid testing kit
  • Brake cleaner spray
  • Brake grease/lubricant
  • Protective gear – gloves, glasses, etc.

Don’t forget the critical replacement part itself – the new brake booster pushrod matched to your vehicle’s year, make and model. Ensure it’s an identical fitment with the original. With your toolkit fully stocked, you’re ready to get elbows-deep in brake repair.

Safety First – Disable the Vehicle’s Power Systems

Any time you’ll be working around a vehicle’s hydraulic, electrical or moving components, it’s absolutely mandatory to disable all systems that could activate and cause injury:

  1. Park your vehicle on level ground and set the parking brake.
  2. Lift the hood and locate the battery.
  3. Disconnect the NEGATIVE (black) cable from the battery terminal.
  4. Tape or otherwise insulate the disconnected cable end to prevent accidental reconnection.

With battery power cut off, you eliminate the possibility of electric fans or other systems kicking on unexpectedly. And remember – NEVER disconnect the RED positive cable first, as that could cause dangerous system shorts!

Accessing the Brake Booster and Master Cylinder

The brake booster and master cylinder hide behind the dashboard, requiring partial disassembly to gain clear access:

  1. Locate the brake booster on the driver’s side firewall.
  2. Use pliers to detach the vacuum hose from the booster.
  3. Remove the bolts fastening the booster to the firewall.
  4. Without pulling too forcefully, wiggle the booster loose.

Be extremely careful not to bend or damage any brake lines running to the master cylinder reservoir. Keep the booster supported until you can detach those lines.

Separating the Master Cylinder from the Booster

With room to work, you can now split the master cylinder and booster:

  1. Use a flare nut wrench to separate the brake line fittings from the master cylinder ports.
  2. Cap the ports to prevent fluid leaks or contamination.
  3. Remove any retaining clips or fasteners connecting the pushrod.
  4. Gently detach the pushrod ball joint from the master cylinder bore without bending it.

Removing the Worn Pushrod from the Booster

On the brake booster side, removing the worn pushrod takes just seconds:

  1. Locate and remove the c-clip or retaining pin holding the pushrod.
  2. Carefully draw the pushrod straight out of the booster housing without bending.

Inspecting and Preparing the New Replacement Part

Before bolting on that shiny new brake booster pushrod, let’s validate it:

  1. Use a caliper to check the replacement matches OEM length and thickness.
  2. Ensure the new ball joint smoothly rotates without binding.
  3. Confirm the pushrod body remains perfectly straight without bends.
  4. Carefully polish any surface corrosion with fine emory cloth.
  5. Apply a thin coating of brake lubricant to the pushrod ball joint.

Once prepped, that fresh pushrod is ready to bolt back on!

Reattaching the Master Cylinder and Pushrod

You’re now ready to reverse the entire process:

  1. Insert the new pushrod straight into the booster housing.
  2. Replace the c-clip or pin to secure it in place
  3. Mate the new pushrod ball joint to the master cylinder bore.
  4. Reinstall any retaining fasteners to connect the joint.
  5. Torque any housing bolts to factory specifications.
  6. Carefully bend aside any brake lines, reconnecting fittings.
  7. Secure the master cylinder and booster assembly back to the firewall.

Bleeding Brakes to Purge Trapped Air

Before the brake pedal feels firm again, you MUST bleed the system:

  1. Refill the master cylinder reservoir with fresh brake fluid.
  2. Have an assistant pump the brake pedal.
  3. Open each caliper’s bleed valve, one line at a time.
  4. Allow fluid to flow until no more bubbles emerge.
  5. Close the bleed valves and have your helper release the pedal.
  6. Repeat bleeding procedure until the pedal feels hard and consistent.
  7. Check fluid levels and top off as needed.

Pro Tip: Use a brake pedal pumping/bleeding device so you don’t need an extra set of hands!

Testing Brake Operation for Safety

You DID remember to reconnect the battery, yes? Hopefully so, because now comes the moment of truth – testing brake performance before hitting the streets again.

Find a large, empty parking lot without obstructions. Accelerate to approximately 15 mph and firm press the brake pedal. Do the brakes respond quickly? Does the pedal feel hard right away without sinking to the floorboard? Can you slow and bring the vehicle to a quick, straight stop without swerving or pulling to one side?

If you feel braking is substandard or unsafe after multiple tests, recheck your pushrod installation and fluid bleed. If performance remains poor, consult a professional brake specialist to inspect your work.

FAQs: Common Brake Booster Pushrod Questions

Do you still have lingering questions about diagnosing or replacing faulty brake booster pushrods? Check these frequently asked mechanical questions:

How can I confirm the pushrod is causing my soft brake pedal?

Start by verifying sufficient brake pad material remains on all 4 wheels. Low fluid level or leaks in the master cylinder can also allow a soft pedal. Check that the pushrod moves in and out without binding when you depress the pedal. Any stiffness indicates wear.

Does pushrod length need to match exactly?

The replacement pushrod MUST precisely match the original equipment part’s length to ensure proper master cylinder bore pressure. Even minor length discrepancies will keep brakes from fully engaging.

What happens if I bend the pushrod during installation?

A bent pushrod prevents smooth linear motion into the brake booster, reducing vacuum assist force. Even slight bends can drastically impair braking capacity. Any time you suspect pushrod damage, replace it.

Is bleeding brakes absolutely necessary after pushrod replacement?

YES! Failing to properly bleed brings a high risk of brake failure. Any air bubbles trapped in brake lines will compress when you brake, causing a spongy pedal preventing full pressure application.

Can I adjust a sticking pushrod rather than replace it?

Never “fix” a sticking or frozen pushrod with lubricants or adjusting. As critical safety components, both the brake booster and master cylinder require precision internal clearances not possible with a damaged rod.

Confidently Handle Your Own Brake Repairs

While brake systems may seem mysterious, armed with the facts in this guide, you have what it takes for hassle-free brake booster pushrod removal and replacement. Just take your time, leverage quality parts and tool, and thoroughly bleed the system afterwards. Before you know it, that soft pedal will be high and firm again, keeping you and your passengers safe!

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