Removal and Installation
WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 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 REMOVAL AND INSTALLATION .
- Remove the PCM. For additional information, refer to REMOVAL 2.5L or REMOVAL 3.0L (4V) .
- Remove the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
- If equipped, remove the brake booster vacuum sensor. For additional information, refer to BRAKE BOOSTER VACUUM SENSOR - NON-HYBRID .
- Remove the bolt and position the ground cable aside.
- To install, tighten the bolt to 12 Nm (106 lb-in).
- Disconnect the harness fastener and remove the 3 nuts and the PCM bracket.
- To install, tighten the nuts to 11 Nm (97 lb-in).
- Disconnect the vacuum hose/check valve assembly from the brake booster.NOTE: Make sure that the aspirator tube is routed correctly and that the clamps are positioned so they do not make contact with surrounding components or damage to the tube may occur.
Automatic transmission vehicles
- Remove the transmission fluid level indicator tube bolt and position the tube aside.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.
- 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 the nuts in a crisscross pattern to 23 Nm (17 lb-ft).
- To install, reverse the removal procedure.
- Check for correct booster push rod distance and adjust as necessary.
- Tighten the booster push rod jam nut to 17 Nm (150 lb-in).
NOTE: Prior to installation, make sure that the distance between the booster mating surface and the push rod center point is as shown in illustration or reduced brake assist may occur. - Check for correct booster push rod distance and adjust as necessary.