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> Brake Booster Replacement
post Dec 2 2006, 10:43 AM
Post #1

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Brake Booster replacement:

First start by Disconnecting the Battery.

Then open the hood and remove the Upper torque mount cross member.

Next remove the Air filter housing.

The remove the Big Cover over the Relay/fuse panel under the hood.
Once the cover is off remove the 13mm nut for the Positive cable.

Then remove the 2 screws securing the Relay box into place.(one of the screws is under where the positive cable just came off)
Unplug the one harness from the box and move the box to the side.

Then reach under and unplug the ABS module. There is 2 plugs. One you have to push a little tab and fold the cover back to release the plug. The other is 2 push tabs then pull.

Ok here is where it will get a little tricky. Look where the ABS pump motor assembly bolts to the body. There is 3 10mm bolts remove them and make sure the pump motor is loose.(No need to disconnect the lines)
Remove the 2 screws holding the Master Cylinder to the booster.
Unplug the sensor in the booster. Remove the Line and Valve from inside the booster.

That should be about it from outside till the booster is loose.

Inside the car:

Remove the Lower dash panel on the drivers side.
Then remove the clip holding the brake pedal to the booster. Either slide the Pin out or slide the Arm off.(Forget which it has). Then remove the 4 13mm screws holding the Booster to the Firewall.

Now go back outside:

Then slide the Master cylinder off of the Booster and kind of pull and move to the side.
Might require Carefully bending some of the lines. Then slide the Booster out.(Most of the times it takes some work to get it slid out. It might take some time to slide it out just take your time.

Then install in reverse order.

It will take a little time to do. About 1/2 a day at home with Hand tools.

Sorry forgot to tell you to make sure you check the adjustment on the brake light switch when you are done.

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post Feb 25 2010, 09:05 AM
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Drives: 2007 Volvo S60 2.5T

Just would like to add a couple of comments: First, like Tech says you don't need to disconnect brake lines from master cylinder or ABS pump. Second, you need to remove air intake hose to the turbo for easy removal of booster.

Thanks Tech for your instructions. (IMG:style_emoticons/default/thumbsup.gif)
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post Aug 16 2010, 10:06 PM
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Location: illinois
Drives: 2000 volvo

thanks for this write up. very interesting. i know that a lot of members looking for this step-by-step instruction on how to replace their brake booster.
cool auto parts
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post May 22 2020, 06:56 PM
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Location: usa
Drives: 2004 volvo XC 90 T6 AWD

Thank you, Iā€™ve recently been searching for information about this topic for a long time and yours is the best I have found out so far. But, what in regards to the conclusion? Are you sure concerning the source?

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