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Brake Booster - SVT: Removal

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the air conditioning (A/C) pressure switch electrical connector.
    Fig 1: Disconnecting Air Conditioning Pressure Switch Electrical Connector
    G01610705Courtesy of FORD MOTOR CO.
  3. Remove the right-hand front wheel and tire. For additional information, refer to WHEELS & TIRES .
  4. Remove the fender splash shield.
    Fig 2: Removing Fender Splash Shield
    G01610706Courtesy of FORD MOTOR CO.
  5. Evacuate the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  6. Remove the radiator. For additional information, refer to ENGINE COOLING .
    7. CAUTION: Over bending of the flexible pipe may cause damage resulting in failure.
    Fig 3: Supporting Flexible Pipe With Wrap Or Splint
    G01610707Courtesy of FORD MOTOR CO.
  7. Support the flexible pipe with a support wrap or suitable splint.
  8. Disconnect the exhaust flexible pipe from the muffler and tailpipe assembly.
    • Discard the gasket and nuts.
      Fig 4: Disconnecting Exhaust Flexible Pipe
      G01610708Courtesy of FORD MOTOR CO.
  9. Detach the engine rear support insulator from the support insulator bracket.
    Fig 5: Detaching Engine Rear Support Insulator From Support Insulator Bracket
    G01610709Courtesy of FORD MOTOR CO.
  10. Lower the vehicle.
  11. Detach the coolant expansion tank from the wheelhouse assembly and position it to one side.
    1. Remove the bolt.
    2. Detach the tank.
      Fig 6: Detaching Coolant Expansion Tank From Wheelhouse Assembly
      G01610710Courtesy of FORD MOTOR CO.
  12. Detach the power steering fluid reservoir from the wheelhouse assembly and position it to one side.
    Fig 7: Detaching Power Steering Fluid Reservoir From Wheelhouse Assembly
    G01610711Courtesy of FORD MOTOR CO.
  13. Disconnect the powertrain control module (PCM) electrical connector.
    Fig 8: Disconnecting Powertrain Control Module Electrical Connector
    G01610712Courtesy of FORD MOTOR CO.
  14. Disconnect the PCM electrical connector bracket.
    Fig 9: Disconnecting PCM Electrical Connector Bracket
    G01610713Courtesy of FORD MOTOR CO.
  15. Disconnect the headlamp wiring harness ground cable.
    Fig 10: Disconnecting Headlamp Wiring Harness Ground Cable
    G01610714Courtesy of FORD MOTOR CO.
  16. Using a suitable hoist support the engine.
    Fig 11: Using A Suitable Hoist Support Engine
    G01610715Courtesy of FORD MOTOR CO.
  17. Detach the engine front mount bracket from the side member.
    Fig 12: Detaching Engine Front Mount Bracket From Side Member
    G01610716Courtesy of FORD MOTOR CO.
    18. CAUTION: Make sure excessive force is not placed on the remaining engine mount when moving the engine forwards.
    Fig 13: Moving Engine Front Mount Towards Front Of Vehicle To Its Maximum Deflection
    G01610717Courtesy of FORD MOTOR CO.
  18. Move the engine front mount towards the front of the vehicle to its maximum deflection.
  19. Detach the PCM wiring harness from the bulkhead.
    Fig 14: Detaching PCM Wiring Harness From Bulkhead
    G01610718Courtesy of FORD MOTOR CO.
  20. Detach the brake tubes from the bulkhead.
    Fig 15: Detaching Brake Tubes From Bulkhead
    G01610719Courtesy of FORD MOTOR CO.
  21. Remove the fuel line.
    Fig 16: Removing Fuel Line
    G01610720Courtesy of FORD MOTOR CO.
    22. CAUTION: Cap the refrigerant line and the evaporator to prevent dirt ingress.
  22. Using the special tool disconnect the accumulator refrigerant line from the evaporator.
    • Discard the O-ring seal.
      Fig 17: Disconnecting Accumulator Refrigerant Line From Evaporator
      G01610721Courtesy of FORD MOTOR CO.
    23. CAUTION: Cap the refrigerant line and the evaporator to prevent dirt ingress.
  23. Using the special tool disconnect the condenser refrigerant line from the evaporator.
    • Discard the O-ring seal.
      Fig 18: Disconnecting Condenser Refrigerant Line From Evaporator
      G01610722Courtesy of FORD MOTOR CO.
  24. Detach the refrigerant lines from the wheelhouse assembly.
    Fig 19: Detaching Refrigerant Lines From Wheelhouse Assembly (1 Of 2)
    G01610723Courtesy of FORD MOTOR CO.
  25. Detach the refrigerant lines from the wheelhouse assembly.
    Fig 20: Detaching Refrigerant Lines From Wheelhouse Assembly (2 Of 2)
    G01610724Courtesy of FORD MOTOR CO.
  26. Remove the refrigerant line retaining bracket.
    Fig 21: Removing Refrigerant Line Retaining Bracket
    G01610725Courtesy of FORD MOTOR CO.
    27. NOTE: Pull the refrigerant line through the fender.
  27. Remove the refrigerant lines from the engine compartment.
  28. Remove the master cylinder. For additional information, refer to BRAKE MASTER CYLINDER .
  29. Detach the brake pedal switches from the brake pedal bracket.
    1. Unlock the switches.
    2. Detach the switches.
      Fig 22: Detaching Brake Pedal Switches From Brake Pedal Bracket
      G01610726Courtesy of FORD MOTOR CO.
  30. Detach the brake booster actuating rod from the brake pedal.
    1. Depress the brake pedal.
    2. Depress the clip.
    3. Remove the brake booster actuating rod pin.
      Fig 23: Detaching Brake Booster Actuating Rod
      G01610727Courtesy of FORD MOTOR CO.
  31. Remove the brake booster retaining nuts.
    Fig 24: Removing Brake Booster Retaining Nuts
    G01610728Courtesy of FORD MOTOR CO.
  32. Disconnect the brake booster solenoid valve electrical connector.
    Fig 25: Disconnecting Brake Booster Solenoid Valve Electrical Connector
    G01610729Courtesy of FORD MOTOR CO.
  33. Remove the brake booster.
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