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Home >> Ford >> 2002 >> Taurus LX, 3.0 S >> Repair and Diagnosis >> External Pages >> Different car >> Section 2531 (Power Brake Actuation -- Brake Booster) >> Removal And Installation >> Brake Booster - Hydro-Boost® >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Always carry the Hydro-Boost® assembly by the casting. The accumulator contains high-pressure nitrogen gas and may be dangerous if dropped or impacted. Check the accumulator snap ring for correct seating prior to installation. Failure to follow these instructions may result in serious personal injury.
WARNING: When disposing of the accumulator, do not expose it to incineration or open flame. Before discarding the accumulator, drill a 1.6 mm (0.06 in) diameter hole in the end of the accumulator can to relieve gas pressure. Failure to follow these instructions may result in serious personal injury.
    NOTE: Do not activate the brake booster with the brake master cylinder removed or damage to the booster may occur.
  1. Remove the brake master cylinder. Refer to HYDRAULIC BRAKE ACTUATION article.
  2. Disconnect the power steering pressure line fittings.
    • Remove and discard Teflon® seals.
    • To install, tighten to 35 Nm (26 lb-ft).
  3. Using the Teflon® Seal Installer Set, install new Teflon® seals on the power steering pressure fittings.
    4. Fig 1: Installing New Teflon(R) Seals On Power Steering Pressure Fittings
    GF0012286Courtesy of FORD MOTOR CO.
  4. Disconnect the power steering fluid return hose.
    • Remove the compression clamp.
    5. Fig 2: Disconnecting Power Steering Fluid Return Hose
    GF0012287Courtesy of FORD MOTOR CO.
    NOTE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.
  5. Remove the stoplamp switch. For additional information, refer to EXTERIOR LIGHTING article.
  6. Disconnect the brake booster push rod in the following sequence.
    1. Remove the brake booster push rod cotter pin cover.
    2. Remove the brake booster push rod cotter pin.
    3. Remove the spacer.
    4. Disconnect the brake booster push rod from the brake pedal pin.
  7. Remove the 4 brake booster nuts and the brake booster.
    • To install, tighten to 25 Nm (18 lb-ft).
    8. NOTE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch.
  8. To install, reverse the removal procedure.
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