Removal and Installation

All vehicles 

1. Remove the brake master cylinder. For additional information, refer to HYDRAULIC BRAKE SYSTEM ACTUATION article.
2. Remove the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article or ELECTRONIC ENGINE CONTROLS - 3.0L (4V) -- FUSION & MILAN article.
3. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
4. If equipped, remove the brake booster vacuum sensor. For additional information, refer to BRAKE BOOSTER VACUUM SENSOR - NON-HYBRID  in this service information.
5. Remove the bolt and position the ground cable aside.
   • To install, tighten the bolt to 12 Nm (106 lb-in).
   Fig 1: Locating Ground Cable Bolt

   Courtesy of FORD MOTOR CO.
6. Disconnect the harness fastener and remove the 3 nuts and the PCM bracket.
   • To install, tighten the nuts to 11 Nm (97 lb-in).
NOTE: Make sure that the aspirator tube is routed correctly and that the clamps are positioned so they do not make contact with surrounding components or damage to the tube may occur.
7. Disconnect the vacuum hose/check valve assembly from the brake booster.

   Automatic transmission vehicles 

NOTE: It is not necessary to remove the fluid level indicator tube from the transmission. The tube can be positioned aside with only the bolt removed.
8. Remove the transmission fluid level indicator tube bolt and position the tube aside.
   • To install, tighten to 8 Nm (71 lb-in).

   All vehicles 

9. Remove the brake booster push rod pin and clip and disconnect the push rod from the brake pedal.
NOTE: Use only hand tools to remove the fasteners or damage to the booster may occur.
10. Remove the 4 nuts and the brake booster.
NOTE: Prior to installation, make sure that the distance between the booster mating surface and the push rod center point is as shown in the illustration or reduced brake assist may occur.
Fig 2: Identifying Correct Booster Push Rod Distance
Courtesy of FORD MOTOR CO.
11. To install, reverse the removal procedure.
    • Check for correct booster push rod distance and adjust as necessary.
    • Tighten the booster push rod jam nut to 17 Nm (150 lb-in).
NOTE: Use only hand tools to install the fasteners or damage to the booster may occur.
12. Tighten the brake booster nuts to 23 Nm (17 lb-ft) in the sequence shown in the illustration.

Fig 3: Identifying Brake Booster Nuts Tightening Sequence

Courtesy of FORD MOTOR CO.