Removal and Installation
WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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. Failure to follow these instructions may result in personal injury.
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. Failure to follow these instructions may result in personal injury.
- With the engine off, apply the brake pedal several times to deplete the brake booster accumulator reserve.
- Disconnect the power steering pressure hoses.
- Using the special tool, install new Teflon® seals on the power steering pressure fittings.
- Disconnect the power steering fluid return hose.
- Remove the brake master cylinder. Refer to HYDRAULIC BRAKE ACTUATION .
- Disconnect the brake booster push rod.
- Remove the stoplamp switch self-locking pin.
- Remove the stoplamp switch.
- Remove the brake booster push rod bushing.
- Disconnect the brake booster push rod from the brake pedal pin.
- Remove the brake booster nuts.
- Remove the brake booster.
- To install, reverse the removal procedure.
- Fill the power steering fluid reservoir. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
CAUTION:
Do not activate the brake booster with the brake master cylinder removed.