Brake Booster - 3.5L, 3.7L: Removal

WARNING: This page is about a different car, the 2014 Lincoln MKX and 2014 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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.

NOTE: 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.

Disconnect the brake booster check valve from the brake booster.
Remove the upper intake manifold. For additional information, refer to ENGINE -3.5L , or ENGINE -3.7L .
NOTE: The braided steel portions of the brake tubes should not be flexed. Do not position the brake master cylinder aside or damage to the brake tubes may result.

Remove the brake master cylinder. For additional information, refer to HYDRAULIC BRAKE ACTUATION .
Disconnect the vacuum hose and wire harness from the studs and remove the brake booster vacuum hose.
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 EXTERIOR LIGHTING .
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.

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