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Brake Booster: Removal

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5 times with the engine not running.
  2. Remove the 4 strut upper mount nuts and remove the strut tower brace.
  3. Remove the ACL  outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  4. Remove HCU  . REFER to HYDRAULIC CONTROL UNIT (HCU) .
  5. Remove the brake master cylinder. REFER to BRAKE MASTER CYLINDER .
  6. Disconnect the brake booster vacuum fitting and position aside.
  7. NOTE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger 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. REFER to STOPLAMP SWITCH .

  8. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time 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 booster push rod clevis-locking pin.

  9. Remove the 4 nuts and remove the brake booster.
    • Discard the nuts.
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