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Home >> Ford >> 2005 >> Expedition RWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Power Brake Actuation -- Brake Booster >> Removal And Installation >> Brake Booster >> Removal and Installation

Removal and Installation

  1. Disconnect the battery negative cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Loosen the clamp and separate the air cleaner outlet tube and resonator from the air cleaner.
    Fig 1: Separating Air Cleaner Outlet Tube And Resonator From Air Cleaner
    G03928794Courtesy of FORD MOTOR CO.
  3. Disconnect the mass air flow (MAF) sensor electrical connector.
    Fig 2: Disconnecting Mass Air Flow Sensor Electrical Connector
    G03928795Courtesy of FORD MOTOR CO.
  4. Lift the air cleaner assembly from the air cleaner tray.
    Fig 3: Lifting Air Cleaner Assembly From Air Cleaner Tray
    G03928796Courtesy of FORD MOTOR CO.
  5. Remove the screws and position aside the power steering reservoir.
    Fig 4: Removing Power Steering Reservoir Screws
    G03928797Courtesy of FORD MOTOR CO.
  6. Disconnect the brake fluid level switch and if equipped, the brake pressure switch.
    Fig 5: Disconnecting Brake Fluid Level Switch And Brake Pressure Switch
    G03928798Courtesy of FORD MOTOR CO.
  7. NOTE: Support the master cylinder with a wire tie or mechanics wire.
    Fig 6: Removing Master Cylinder Nuts
    G03928799Courtesy of FORD MOTOR CO.
  8. Remove and discard the two nuts and position the master cylinder aside.
  9. Remove the mounting bolts for the degas bottle and position aside.
    Fig 7: Removing Mounting Bolts For Degas Bottle
    G03928800Courtesy of FORD MOTOR CO.
  10. If equipped, disconnect the wiring at the pedal travel sensor and solenoid.
    Fig 8: Disconnecting Wiring At Pedal Travel Sensor And Solenoid
    G03928801Courtesy of FORD MOTOR CO.
  11. Release the clamp and disconnect the hose.
    Fig 9: Releasing Hose Clamp
    G03928802Courtesy of FORD MOTOR CO.
  12. Remove the pin, washer, bushing and switch, and disconnect the booster pushrod.
    Fig 10: Removing Booster Pushrod
    G03928803Courtesy of FORD MOTOR CO.
  13. Remove the nuts and the brake booster.
    • To access the retaining nuts, fold back the sound insulation.
  14. NOTE: The booster pushrod must be installed with the pushrod offset pointing downward.
  15. To install, reverse the removal procedure.
  16. Use new nuts when installing the master cylinder.
    Fig 11: Installing Master Cylinder Nuts
    G03928789Courtesy of FORD MOTOR CO.