Removal and Installation

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.

CAUTION: Do not depress the brake pedal while the hydraulic fluid supply line is disconnected. The inlet pressure port check ball may be dislodged which will result in a non-functional backup system.

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the support bracket bolt and nut.

Fig 1: Removing Support Bracket Bolt And Nut
Courtesy of FORD MOTOR CO.
Remove the ground wire nut and the ground wire.

Fig 2: Removing Ground Wire Nut And Ground Wire
Courtesy of FORD MOTOR CO.
Remove the four master cylinder nuts.

Fig 3: Removing Four Master Cylinder Nuts
Courtesy of FORD MOTOR CO.
Position the master cylinder aside.

Fig 4: Positioning Master Cylinder Aside
Courtesy of FORD MOTOR CO.
Remove the electric motor relay bolt.

Fig 5: Removing Electric Motor Relay Bolt
Courtesy of FORD MOTOR CO.
Disconnect the flow switch electrical connector.

Fig 6: Disconnecting Flow Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the steering column cover.

Fig 7: Removing Steering Column Cover
Courtesy of FORD MOTOR CO.
Remove the brake pedal position (BPP) switch self-locking pin.

Fig 8: Removing Brake Pedal Position Switch Self-Locking Pin
Courtesy of FORD MOTOR CO.
Remove the brake pedal position (BPP) switch and the brake booster push rod from the brake pedal.

Fig 9: Removing Brake Pedal Position Switch
Courtesy of FORD MOTOR CO.
Disconnect the electric pump and motor assembly electric connector.

Fig 10: Disconnecting Electric Pump And Motor Assembly Electric Connector
Courtesy of FORD MOTOR CO.
Disconnect the hydraulic fluid return hose.

Fig 11: Disconnecting Hydraulic Fluid Return Hose
Courtesy of FORD MOTOR CO.
Remove the hydraulic fluid supply line nut.

Fig 12: Removing Hydraulic Fluid Supply Line Nut
Courtesy of FORD MOTOR CO.
Remove the Hydro-Max booster nuts, and remove the Hydro-Max booster.

Fig 13: Removing Hydro-Max Booster Nuts (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 14: Removing Hydro-Max Booster Nuts (2 Of 2)
Courtesy of FORD MOTOR CO.

NOTE: Start the hydraulic fluid supply line before tightening the Hydro-Max nuts and bolts.

Fig 15: Installing Hydro-Max Booster Nuts (1 Of 2)

G01439595

Courtesy of FORD MOTOR CO.

Fig 16: Installing Hydro-Max Booster Nuts (2 Of 2)

G01439596

Courtesy of FORD MOTOR CO.

Fig 17: Installing Hydraulic Fluid Supply Line Nut

G01439597

Courtesy of FORD MOTOR CO.

Fig 18: Installing Electric Motor Relay Bolt

G01439598

Courtesy of FORD MOTOR CO.

Fig 19: Installing Four Master Cylinder Nuts

G01439599

Courtesy of FORD MOTOR CO.

Fig 20: Installing Ground Wire Nut And Ground Wire

G01439600

Courtesy of FORD MOTOR CO.

Fig 21: Installing Support Bracket Bolt And Nut

G01439601

Courtesy of FORD MOTOR CO.

To install, reverse the removal procedure.