How to Remove Brake Boosters on a 1993 Volkswagen Jetta

The brake booster, also referred to as the power booster on a 1993 Volkswagen is a round steel cylinder sandwiched between the master cylinder and the firewall. The brake booster uses engine vacuum to increase the force exerted on the brakes when the driver presses the brake pedal. The power booster also lessens the distance the brake pedal must travel before the brakes engage. Removing the brake booster on a 1993 Jetta is a reasonably easy task that can be accomplished by the home mechanic in a few hours.

Instructions

Removing the Master Cylinder on a Manual Brake System

1

Disconnect the ground cable from the negative battery terminal by loosening the retaining bolt, using a wrench. Then pull the clamp off the terminal.

2

Unscrew the master cylinder reservoir cap by turning it counterclockwise with your hand.

3

Drain the brake fluid form the master cylinder reservoir.

4

Unscrew the brake line fittings from the bottom of the master cylinder using a line wrench. Then pull the lines away from the master cylinder. Be aware some fluid might leak from the master cylinder.

5

Cover the brake line ends and the orifices in the master cylinder with electrical tape, to prevent dirt and oil from entering the hydraulic system.

6

Unscrew the two nuts and washers that secure the master cylinder to the brake booster using a socket.

7

Slide the master cylinder forward and away from the power booster, then remove it from the vehicle.

Removing the Brake Light Switch

8

Carefully pull the vacuum line out of the brake booster using your hand.

9

Locate the brake light switch on the the brake pedal bracket.

10

Remove the fuse box cover, by pressing in the locking buttons with your fingers and pulling the cover away.

11

Remove the screws that secure the under dash trim panel to the dash.

12

Remove the trim panel, by pulling it downward and carefully pry it away from the dash. Then remove it from the vehicle.

13

Pull the wiring connector off the back of the switch with your hand.

14

Rotate the switch 90 degrees then pull it from the bracket with your hand.

Removing the Brake Booster

15

Unscrew the four brake booster mounting nuts, using a socket. They are located inside the vehicle at the brake pedal mounting bracket.

16

Slide the brake booster forward slightly, until you can see the brake pedal pushrod coming out of the back of the booster.

17

Spread the retaining clips that secure the brake pedal pushrod to the power booster, using your hand. The pull the pushrod from the booster.

18

Lift the brake booster from the engine bay.