Removal And Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death.

WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

NOTE: Brake fluid reservoir shown removed for clarity.

Disconnect the battery. For additional information refer to BATTERY, MOUNTING AND CABLES article.
Depower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.

CAUTION: Do not service the brake pedal, brake booster or master cylinder without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers 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.

Remove the stoplamp switch. For additional information, refer to EXTERIOR LIGHTING article.
If equipped, remove the speed control deactivator switch. For additional information, refer to SPEED CONTROL article.
Using a suitable suction device, remove the brake fluid from the master cylinder reservoir.
Disconnect the brake fluid level switch electrical connector.
Disconnect the brake travel sensor electrical connector.
Disconnect and cap the 2 brake tube fittings.
- To install, tighten to 14 Nm (10 lb-ft).
Loosen the return hose clamp and disconnect the return hose.
- To install, tighten to 3 Nm (27 lb-in).
Loosen the feed hose clamp and disconnect the feed hose.
- To install, tighten to 3 Nm (27 lb-in).

NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster push rod clevis locking pin is removed, a new booster push rod clevis locking pin should be used.

NOTE: Remove the clevis locking pin by squeezing the locking tabs and pulling outward on the opposite end.

Remove and discard the booster push rod clevis locking pin.
Remove the 4 brake master cylinder nuts.
- To install, tighten to 23 Nm (17 lb-ft).
Remove the brake master cylinder.

CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.

To install, reverse the removal procedure.
- Repower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION article.