Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

Remove the brake master cylinder. For additional information, refer to HYDRAULIC BRAKE ACTUATION .
Remove the powertrain control module (PCM). For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.3L or ELECTRONIC ENGINE CONTROLS - 3.0L (4V) .
Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the bolt and disconnect the PCM ground.

Fig 1: Locating Bolt And PCM Ground
Courtesy of FORD MOTOR CO.
Disconnect the brake tube clip, the 3 nuts and remove the PCM bracket.

Fig 2: Locating Nuts And PCM Bracket
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the aspirator tube is routed correctly and that the clamps are positioned so they do not make contact with surrounding components.

Disconnect the vacuum hose/check valve assembly from the brake booster.

Automatic transmission vehicles

NOTE: It is not necessary to remove the fluid level indicator tube from the transmission. The tube can be positioned aside with only the bolt removed.

Remove the transmission fluid level indicator tube bolt and position the tube aside.
- To install, tighten to 8 Nm (71 lb-in).

All vehicles

Remove the brake booster push rod pin and clip and disconnect the push rod from the brake pedal.
Remove the 4 nuts and the brake booster.
- To install, tighten to 23 Nm (17 lb-ft).

CAUTION: Prior to installation, make sure that the distance between the booster mating surface to the push rod center point is as shown.

To install, reverse the removal procedure.
- Check for correct booster push rod distance and adjust as necessary.
  - Tighten booster push rod jam nut to 17 Nm (13 lb-ft).
    
    Fig 3: Identifying Booster Push Rod Distance
    Courtesy of FORD MOTOR CO.