Good evening,
The booster has a vacuum leak and it is leaking out the shaft at the pedal.
I would replace the booster assembly.
Roy
Procedure
Power Vacuum Brake Booster Replacement
Removal Procedure
Caution: Refer to Brake Fluid Irritant Caution (See: Brakes and Traction Control > Technician Safety Information > Brake Fluid Irritant Caution).
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (See: Brakes and Traction Control > Vehicle Damage Warnings > Brake Fluid Effects on Paint and Electrical Components Notice).
1. Relieve fuel line pressure. Refer to Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Release > Procedures > Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Release > Procedures > Fuel Pressure Relief (Without CH 48027)).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill LZ9) (See: Cooling System > Removal and Replacement)Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System > Removal and Replacement).
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement (See: Coolant Reservoir > Removal and Replacement).
4. Remove the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement (Pontiac) (See: Structural Brace > Removal and Replacement)Front End Sheet Metal Diagonal Brace Replacement (Chevrolet) (See: Structural Brace > Removal and Replacement).
5. Remove the engine control module (ECM) cover from the air cleaner housing.
6. Remove the ECM and set aside. It is not necessary to disconnect the electrical connector. Refer to Engine Control Module Replacement (See: Engine Control Module > Removal and Replacement).
7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing > Removal and Replacement > Air Cleaner Assembly Replacement).
8. Remove the fuel lines from the pipes and vapor line. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler > Removal and Replacement > Metal Collar Quick Connect Fitting Service) orPlastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler > Removal and Replacement > Plastic Collar Quick Connect Fitting Service).
9. Remove the heater hose from the coolant cross over pipe and reposition out of the way. Refer to Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement (See: Heater Hose > Removal and Replacement > Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement).
10. Release the fuel lines from the shock tower for easier access to the brake pipes.
11. Disconnect the fluid level sensor switch from the brake master cylinder.
12. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement (See: Brake Master Cylinder > Removal and Replacement > Master Cylinder Replacement).
13. Remove the brake pressure modulator valve (BPMV) assembly and bracket. Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes > Removal and Replacement).
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Wednesday, February 13th, 2019 AT 3:39 PM