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Home >> Ford >> 2005 >> Excursion 5.4 L, 4WD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Power Brake Actuation -- Brake Booster >> Removal And Installation >> Brake Booster - Vacuum >> Removal and Installation

Removal and Installation

  1. Disconnect the battery. For additional information, REFER to BATTERY, MOUNTING AND CABLES .
  2. Remove the air cleaner housing. For additional information, REFER to INTAKE AIR DISTRIBUTION & FILTERING .
  3. Remove the brake master cylinder nuts.
    Fig 1: Removing Brake Master Cylinder Nuts With Torque Specifications
    G03904880Courtesy of FORD MOTOR CO.
  4. Position the brake master cylinder aside.
    Fig 2: Positioning Brake Master Cylinder Aside
    G03904881Courtesy of FORD MOTOR CO.
  5. Disconnect the booster vacuum hose.
    Fig 3: Disconnecting Booster Vacuum Hose
    G03904882Courtesy of FORD MOTOR CO.
  6. Disconnect the power distribution box auxiliary relay and set aside.
    Fig 4: Disconnecting Power Distribution Box Auxiliary Relay
    G03904883Courtesy of FORD MOTOR CO.
  7. Remove the instrument panel steering column opening cover.
    Fig 5: Removing Instrument Panel Steering Column Opening Cover
    G03904876Courtesy of FORD MOTOR CO.
  8. Remove the brake pedal position (BPP) switch self-locking pin.
    Fig 6: Locating Redundant Self-Locking Clip Cover And Self-Locking Clip
    G03904855Courtesy of FORD MOTOR CO.
  9. Remove the BPP switch and the brake booster push rod from the brake pedal pin.
    Fig 7: Locating BPP Switch
    G03904856Courtesy of FORD MOTOR CO.
  10. Remove the power brake booster nuts.
    Fig 8: Removing Power Brake Booster Nuts With Torque Specifications
    G03904879Courtesy of FORD MOTOR CO.
  11. Remove the power brake booster.
    Fig 9: Removing Power Brake Booster
    G03904888Courtesy of FORD MOTOR CO.
  12. To install, reverse the removal procedure.