Brake Booster: Removal
WARNING: This page is about a different car, the 2016 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
NOTE:
Removal steps in this procedure may contain installation details.
- 1.WARNING: Before beginning any service procedure in this service information, refer to Safety Warnings in GENERAL INFORMATION (EXCEPT HYBRID) . Failure to follow this instruction may result in serious personal injury.
Refer to: Health and Safety Precautions .
- 2.
Remove the battery tray. Refer to: Battery Tray .
- 3.
Remove the nut, bolt and the battery tray support bracket.Torque
: 18 lb.ft (24 Nm)
- 4.
Detach the brake tube retainer, disconnect the brake fluid level sensor electrical connector and if equipped, disconnect the clutch master cylinder supply tube.
- 5.NOTE: Before removing the master cylinder, relieve the vacuum in the brake booster or the master cylinder O-ring seal may be drawn into the brake booster, causing brake booster failure and increased brake pedal effort.
Fully apply and release the brake pedal 5 times.
- 6.
- 1.
Disconnect the brake tube fittings.Torque
: 18 lb.ft (25 Nm)
- 2.
Remove the nuts and remove the brake master cylinder and brake tubes as an assembly. Discard the nuts.Torque
: 159 lb.in (18 Nm)
- 1.
- 7.
-
NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
Discard the O-ring seal.
-
- 8.
- 1.
Disconnect the brake booster vacuum sensor electrical connector.
- 2.
Detach the vacuum check valve from the booster and position aside.
- 1.
- 9.
Remove the stud bolt and position the tube aside.Torque
: 133 lb.in (15 Nm)
- 10.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.
Refer to: Stoplamp Switch .
- 11.
Compress the tabs and remove the clevis pin. Discard the pin.
- 12.
Remove the screws and the lower steering column shroud.
- 13.
Remove and discard the nuts.Torque
: 17 lb.ft (23 Nm)
- 14.
Remove the bolt and position the HCU off of the stud.Torque
: 177 lb.in (20 Nm)
- 15.
Remove the brake booster.