2002 BMW 525i Brake Booster Replacement Cost

Brake boosters operate by multiplying the force applied to the brake pedal. When the brake pedal is pressed, it pushes a rod into the brake booster. Then, the brake booster instantaneously pushes the master cylinder with much greater force, allowing the driver to press the brakes with ease, yet creating a great deal of stopping power.

When the brake booster fails, the braking pressure needed at the brake pedal increases dramatically, and, in some cases, the brakes may seem unresponsive. For vacuum boosters, failure will generally create a vacuum leak, and the vehicle may run roughly, become hard to start, misfire at engine idle, and exhibit poor fuel mileage. The check engine light may also illuminate, and OBD trouble codes for engine misfires, lean air/fuel mixture, and intake manifold pressure will be stored in the computer. If the brake system uses they hydro-boost system, there will likely be a power steering fluid leak on the ground, and the brakes will be very difficult or impossible to press.

It is not safe to operate any vehicle with any braking problem. If there's any sign that the brakes are not performing as originally intended, the vehicle should immediately be placed out of service and repaired.

Normally, a vacuum booster will last from 150,000 miles to the lifetime of the vehicle. In especially dry climates, dry rot may cause deterioration of the internal diaphragm, and require replacement.

Diagnosing a vacuum or hydro-boost system is typically simple. The servicing technician may only need to feel the brake pedal with the engine running, and, noting the difficulty, immediately suspect brake booster failure. The booster will then be tested manually, and confirmed faulty upon failure of those tests. For vacuum boost systems, this means sucking the air from the booster, and observing pressure drop. For hydraulic systems, the hydraulic pressure going into the booster must be measured. If the pressure is within specification, yet the brake booster does not function, the technician will understand there is an issue with the booster, and recommend replacement.

Once a diagnosis has been reached, the brake booster must be disconnected from the vehicle by removing the master cylinder, brake booster vacuum or hydraulic lines, and finally the brake booster.

If the vehicle uses a hydraulic booster, it is recommended to flush the power steering system as the faulty brake booster may have allowed debris to travel through the system.

The brake booster bolts to the firewall directly opposite the brake pedal. Some manufacturer's have provided the bolts to remove the booster on the exterior of the vehicle, but others have placed the bolts behind the dashboard. The location of these bolts may negatively or positively impact repair cost, and time.

The braking system can be maintained by a DIYer with plenty of knowledge of hydraulic and vacuum systems. This is important as diagnostics and proper completion of the repair require this knowledge.