Replacement procedure (from memory)
Its not too hard to replace the hydraulic unit. It took me about an hour and a half in my driveway without any assistance (and I was working at slow pace). First thing to do is disconnect the battery, remove the windshield cowling and disconnect the electrical connectors from the old unit. Then go under the dash and disconnect the clip that holds the brake light switch on the brake pedal and the connectors for the cruise control (if applicable). Be sure to take note of how the switch bracket and switch are hooked up so that you can get them back on correctly. Disconnect the actuator "plunger rod" from the brake pedal. At this point you can loosen the nuts on the studs coming through the firewall that secure the pump. Once they are loose, go back up top and very carefully disconnect the brake lines from the pump. After they are disconnected, go back under the dash and remove the nuts from the studs. Now you can remove the hydraulic pump from the engine bay. You will have to play with it a little to get it free from the mess of vacuum lines, wires, etc., but with some patience and careful turning and twisting, it will slide right out. Replacement is the reverse...slide the new unit in, put the nuts on the studs, but leave them loose. (This will help in re-attaching the brake lines). From the top, attach the brake lines (be carefull not to pinch them, or crossthread the fittings), and hook up the electrical connectors. From underneath, tighten down the nuts on the mounting studs and reconnect the brakelight switch bracket and the actuator. You will need to bleed the brakes (or have them bled at a shop), and test the brake lights to make sure the switch is functioning properly when you step on the pedal. You may need to fiddle with the brakelight switch some to get the pedal response set right.
I don't think I have forgotten anything, but it has been a while since I did this.
