Removal and Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: The power brake booster should not be carried by the accumulator, nor should it ever be dropped on the accumulator. Check the snap ring on the accumulator for correct 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. 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.

With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.
Disconnect the battery ground cable (14301). On vehicles equipped with dual batteries. Refer to BATTERY, MOUNTING AND CABLES .
Remove the left side battery (10655). Refer to BATTERY, MOUNTING AND CABLES .
Remove the air cleaner housing.
Remove the brake pressure switch electrical connector.

Fig 1: Removing Brake Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the power steering hoses.

Fig 2: Disconnecting Power Steering Hoses
Courtesy of FORD MOTOR CO.
Remove the brake master cylinder nuts.

Fig 3: Removing Brake Master Cylinder Nuts
Courtesy of FORD MOTOR CO.
Remove the power steering hose mounting bracket and the brake master cylinder (2140), and position aside.

Fig 4: Removing Power Steering Hose Mounting Bracket And Brake Master Cylinder
Courtesy of FORD MOTOR CO.
Remove the instrument panel steering column opening cover.

Fig 5: Removing Instrument Panel Steering Column Opening Cover
Courtesy of FORD MOTOR CO.
Remove the self-locking pin.

Fig 6: Removing Self-Locking Pin
Courtesy of FORD MOTOR CO.
Remove the brake pedal position (BPP) switch (13480) and the brake booster push rod from the brake pedal pin.

Fig 7: Removing Brake Pedal Position (BPP) Switch And Brake Booster Push Rod From Brake Pedal Pin
Courtesy of FORD MOTOR CO.
Remove the power brake booster nuts, and remove the power brake booster.

Fig 8: Removing Power Brake Booster Nuts, And Power Brake Booster
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- Install new O-ring seals on the power steering pressure fittings.
- Bleed Hydro-Boost. Refer to Hydro-Boost Bleeding .