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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.
  1. With the engine off, apply the brake pedal several times to deplete the brake booster vacuum reserve.
  2. Remove the brake master cylinder. For additional information, refer to HYDRAULIC BRAKE ACTUATION .
  3. Disconnect the brake booster check valve.
    Fig 1: Disconnecting Brake Booster Check Valve
    G03891551Courtesy of FORD MOTOR CO.
  4. Disconnect the brake booster push rod.
    1. Remove the stoplamp switch self-locking clip.
    2. Remove the stoplamp switch.
    3. Remove the brake booster push rod bushing.
    4. Disconnect the brake booster push rod from the brake pedal pin.
      Fig 2: Disconnecting Brake Booster Push Rod
      G03891527Courtesy of FORD MOTOR CO.
  5. Remove the brake booster nuts.
    Fig 3: Removing Brake Booster Nuts
    G03891529Courtesy of FORD MOTOR CO.
  6. Remove the brake booster.
    Fig 4: Removing Brake Booster
    G03891554Courtesy of FORD MOTOR CO.
  7. To install, reverse the removal procedure.
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