1997 Z71 Brake Booster replacement

[bcrooms]

My 1997 Z71 has a bad brake booster and needs replacement..I attempted to do it myself, but I am struggling at removing the brake light switch from the brake booster "plunger".

 

Any tips or tricks that you know to make this replacement easier? I just don't want to break the clips on this thing and have to get another one...

[Bigfutz]

My 1997 Z71 has a bad brake booster and needs replacement..I attempted to do it myself, but I am struggling at removing the brake light switch from the brake booster "plunger".
 
Any tips or tricks that you know to make this replacement easier? I just don't want to break the clips on this thing and have to get another one...

I did it and it’s super easy once you get the right trick, I just can’t remember what the trick was. Sorry. The hardest part for me was getting to the 15mm nuts without removing the steering column. I found a tiny 3/8 clickless ratchet at Northern Tool that did the trick. Factory nuts have blue Loctite on them. Maybe an air ratchet could help - I didn’t use one.

The job CAN be done without taking the brake lines off, but you’re going to feel like you’re about to break something bowing the master cylinder out of the way.

[bcrooms]

On 9/12/2020 at 3:41 PM, Bigfutz said:

I did it and it’s super easy once you get the right trick, I just can’t remember what the trick was. Sorry. The hardest part for me was getting to the 15mm nuts without removing the steering column. I found a tiny 3/8 clickless ratchet at Northern Tool that did the trick. Factory nuts have blue Loctite on them. Maybe an air ratchet could help - I didn’t use one.

The job CAN be done without taking the brake lines off, but you’re going to feel like you’re about to break something bowing the master cylinder out of the way.

I am able to remove the master cylinder without any issue, I'm just struggling with removing the interior nuts at the firewall.  I may have to find a ratcheting wrench or something to get them off.  I also don't have a proper pry tool to remove the brake light switch clip

[KINGENGINEMAINTENANCE]

An impact joint adapter comes in handy for those interior nuts and yes that clip can break easily so be aware of that. Cheers

[bcrooms]

Got the booster replaced finally, and all is well again!