Brake Booster: 2.0L: Removal

NOTE: Removal steps in this procedure may contain installation details.

NOTE: The brake booster check valve must be disconnected from the brake booster prior to removing the master cylinder or the master cylinder seal may be drawn into the brake booster.

Fig 1: Locating Vacuum Check Valve Of Power Brake Booster

Courtesy of FORD MOTOR CO.

Make sure that the vacuum hose assembly is routed correctly so it does not make contact with surrounding components or damage to the hose may occur.
Remove the brake master cylinder. Refer to BRAKE MASTER CYLINDER .
To install, tighten the nut to 9 Nm (80 lb-in).

Fig 2: Locating Transmission Control Module Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
To install, tighten to 25 Nm (18 lb-in).

Fig 3: Identifying Hydraulic Unit Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not service the brake booster without first removing the stoplamp switch. Remove this switch 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) results in damage to the switch.

Remove the stoplamp switch. For additional information, refer to STOPLAMP SWITCH .

NOTE: The booster push rod clevis locking pin is a one-time use only part. Any time the pin is removed, a new one must be installed.

NOTE: An 11 mm, 12-point socket or wrench can be used to compress the 2 tabs on the locking pin.

Fig 4: Identifying Booster Push Rod Clevis Locking Pin

Courtesy of FORD MOTOR CO.

To install, tighten to 23 Nm (17 lb-ft).