Vacuum brake booster (Discovery 1)

Note: The brake booster cannot be repaired. Only the filter, check valve and rubber spacer are replaced.

Removal

1. Disconnect the battery.

2. Disconnect the brake fluid level sensor connector.

3. Thoroughly clean the brake pipe connection points. Unscrew the tube fasteners and plug the tubes and fittings.

4. Disconnect the vacuum hose from the brake booster.

5. Remove the bottom panel to access the booster pushrod (on the brake pedal).

6. Remove the cotter pin (or a clip) fixing the pusher on the pedal.

7. Unscrew the two nuts securing the amplifier.



8. Remove the booster assembly with the master cylinder.

9. Drain the fluid from the brake cylinder reservoir.

10. Remove the amplifier mounting spacer.

Note: Save the spacer for later assembly as it determines the size of the amplifier drive chain.

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11. Transfer the master cylinder to the new booster.

Installation

12. Install the spacer on the amplifier.

13. Install the amplifier in place.

14. Lightly lubricate the connection point of the booster pushrod to the brake pedal with grease.



15. Connect the push rod to the bottom hole of the pedal. Install the cotter pin.

16. Tighten the booster mounting nuts to 26 Nm.

17. Reinstall the removed parts and bleed the brake system.