1. Preparation:
* Gather tools: You'll need sockets (various sizes), wrenches, screwdrivers (Phillips and flathead), a vacuum pump or gauge to test the booster after installation (optional but recommended), and possibly a breaker bar for stubborn bolts. A helper can be very useful.
* Safety first: Wear safety glasses and gloves. Brake fluid is corrosive. Have rags ready to clean up any spills.
* Locate the booster: It's usually mounted on the firewall, behind the master cylinder.
2. Disconnect Components:
* Vacuum hose: Carefully disconnect the vacuum hose from the booster. Note its location for reassembly. A small amount of vacuum may escape.
* Brake lines: If accessible, disconnect the brake lines from the master cylinder. If you disconnect brake lines, you MUST properly bleed the brakes after reassembly to remove air. This is very important and usually requires a second person. This might require a line wrench.
* Master cylinder: Depending on your Blazer's configuration, you may or may not need to remove the master cylinder to access the brake booster. This is often easier to do with the booster out of the way.
* Pushrod: Disconnect the pushrod that connects the brake pedal to the booster. Note its position. It might have a clip or nut holding it in place.
3. Removing the Booster:
* Bolts: The booster is typically attached to the firewall with several bolts. Locate and remove these bolts. They can be difficult to reach, so patience is key. Use penetrating oil if the bolts are rusted or seized.
* Removal: Once the bolts are out, carefully remove the booster. It may be a tight fit, so gently wiggle it free.
4. Reassembly (in reverse order):
* Installation: Carefully install the new or refurbished booster. Make sure the pushrod is properly connected and adjusted.
* Reconnect components: Reconnect the vacuum hose, brake lines (if disconnected), and the pushrod.
* Bleed the brakes (if necessary): If you disconnected any brake lines, you MUST bleed the brakes to remove any air that entered the system. This is crucial for proper braking. Follow the bleeding procedure in your repair manual.
* Test the brakes: After reassembly, test the brakes thoroughly in a safe area, ensuring proper function. If the booster isn't working correctly, you'll need to troubleshoot the vacuum system. A vacuum gauge or pump is highly recommended here.
Important Considerations:
* Repair Manual: A repair manual specific to your 1995 Chevy Blazer is highly recommended. This will provide detailed diagrams, torque specifications, and step-by-step instructions.
* Professional Help: If you're uncomfortable performing this repair yourself, consider seeking help from a qualified mechanic. Improperly working brakes are extremely dangerous.
* Vacuum System: Make sure your vehicle's vacuum system is functioning correctly. A leak in the vacuum lines can prevent the booster from working properly.
This is a general guide. Variations in the exact process may exist depending on your specific Blazer model. Always prioritize safety and consult a reliable repair manual before beginning any automotive repair.
