2026-03-12

Brake Booster Assembly (DPB) (RHD) (Model Y L) (Remove and Replace)

Correction code NEW FRT 1.38 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-03-11: Released new procedure.

Remove

  1. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  2. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  3. Remove the wiper module. See Wiper Module - RHD (Remove and Replace).
  4. Remove the RH wiper bracket pencil brace. See Pencil Brace - Wiper Bracket - RH (Remove and Replace).
  5. Remove the driver footwell hush panel. See Hush Panel - Footwell - Driver (Remove and Replace).
  6. Place an absorbent material underneath the brake lines and brake fluid reservoir area.
  7. Clean area around the brake fluid reservoir and remove the brake reservoir cap.
  8. Using a brake fluid evacuator, remove the brake fluid from the reservoir.
  9. Disconnect the brake fluid level sensor connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not push down on the red tab. Pull the red tab to disengage the lock; pull again to release the connector.
  10. Release the connector lock, and then disconnect the brake booster ECU harness connector.
  11. Remove the nut that attaches the master cylinder secondary pipe to the brake booster.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flare Nut Wrench 6pt 12mm
  12. Remove the nut that attaches the master cylinder primary pipe to the brake booster.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flare Nut Wrench 6pt 12mm
  13. Release the cotter clip that attaches the brake clevis clip pin to the brake pedal assembly.
  14. Remove the brake clevis clip pin from the brake pedal assembly.
  15. Remove and discard the nuts (x2) that attach the brake assembly to the bulkhead, and then remove the brake booster assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull straight out first to clear the brake pedal from IP carrier rod before lifting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place an absorbent material beneath the brake booster assembly during removal.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 3/8" DR, DEEP, 13MM

Replace

  1. Position the brake booster to the vehicle, and then install new nuts (x2) (1111541-00-A) that attach the brake assembly to the bulkhead.
    16.5 Nm (12.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 3/8" DR, DEEP, 13MM
  2. Align the brake pedal to the iBooster rod, and then install the brake clevis clip pin to the brake pedal assembly.
  3. Install the cotter clip that attaches the brake clevis clip pin to the pedal assembly.
  4. Install the driver footwell hush panel. See Hush Panel - Footwell - Driver (Remove and Replace).
  5. Install the nut that attaches the master cylinder primary pipe to the brake booster.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flare Nut Wrench 6pt 12mm
  6. Install the nut that attaches the master cylinder secondary pipe to the brake booster.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flare Nut Wrench 6pt 12mm
  7. Connect the brake booster ECU harness connector.
  8. Connect the brake fluid level sensor connector.
  9. Install the RH wiper bracket pencil brace. See Pencil Brace - Wiper Bracket - RH (Remove and Replace).
  10. Install the wiper module. See Wiper Module - RHD (Remove and Replace).
  11. Connect the LV battery. See LV Power (Disconnect and Connect) (Modify).
  12. Remove the front wheel caps. See Cap - Wheel (Model YL) (Remove and Replace).
  13. Bleed and fill the brake fluid. See .
  14. Install the front wheel caps. See Cap - Wheel (Model YL) (Remove and Replace).
  15. Install the air intake duct. See Duct - Air Intake (Remove and Replace).
  16. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  17. Perform a road test to make sure there is proper pedal feel and brake performance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add test drive correction code 00040100 as a separate activity to the Service Visit.