Brake Booster - Hydro-Boost, E150 - E450: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: The power brake booster must not be carried by the accumulator, nor should it ever be dropped on the accumulator. The snap ring on the accumulator must be checked for proper seating before the power brake booster is used. The accumulator contains high-pressure nitrogen gas and can be dangerous if mishandled.

WARNING: If the accumulator is to be disposed of, it must not be exposed to excessive heat, fire or incineration. Before discarding the accumulator, drill a 1.6-mm (1/16-inch) diameter hole in the end of the accumulator can to relieve the gas pressure. Always wear safety glasses when performing this operation.

CAUTION: Do not activate the power brake booster with the brake master cylinder removed.

With the engine off, depress the brake pedal several times to discharge the accumulator.
Disconnect the battery ground cable. On vehicles equipped with dual batteries, disconnect both ground cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Disconnect the power steering pressure hoses.

Fig 1: Disconnecting Power Steering Pressure Hoses
Courtesy of FORD MOTOR CO.
Install new Teflon(R) seals on the power steering pressure fittings.

Fig 2: Installing Teflon Seals On Power Steering Pressure Fittings
Courtesy of FORD MOTOR CO.
Disconnect the power steering return line hose.

Fig 3: Disconnecting Power Steering Return Line Hose
Courtesy of FORD MOTOR CO.
Remove the two nuts and the metal line retainer.

Fig 4: Removing Nuts And Metal Line Retainer
Courtesy of FORD MOTOR CO.
Remove the power distribution box bracket bolts and position the box aside.

Fig 5: Removing Power Distribution Box Bracket Bolts (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 6: Removing Power Distribution Box Bracket Bolts (2 Of 2)
Courtesy of FORD MOTOR CO.
Remove the nuts and position the brake master cylinder aside.

Fig 7: Removing Nuts And Position Brake Master Cylinder Aside
Courtesy of FORD MOTOR CO.
Disconnect the low brake fluid level switch connector.

Fig 8: Disconnecting Low Brake Fluid Level Switch Connector
Courtesy of FORD MOTOR CO.
Disconnect the speed control deactivator switch.

Fig 9: Disconnecting Speed Control Deactivator Switch
Courtesy of FORD MOTOR CO.
Remove the stop light switch self-locking pin.

Fig 10: Removing Stop Light Switch Self-Locking Pin
Courtesy of FORD MOTOR CO.
Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin.

Fig 11: Removing Stoplight Switch And Brake Booster Push Rod
Courtesy of FORD MOTOR CO.
Remove the power brake booster nuts and remove the power brake booster.

Fig 12: Removing Power Brake Booster Nuts
Courtesy of FORD MOTOR CO.