Brake Booster - 2.3L EcoBoost (201kW/273PS): Removal

All vehicles 

• 1.
  
  Remove the cowl panel grill. Refer to: Cowl Panel Grille .

• 2.
  
  Detach the vacuum check valve from the booster and position aside.

Courtesy of FORD MOTOR COMPANY

Vehicles with manual transmission 

• 3.
  
  Remove the brake fluid reservoir cap.

Courtesy of FORD MOTOR COMPANY

• 4.
  
  Using a suitable suction device, syphon the brake fluid from the brake fluid reservoir.

Courtesy of FORD MOTOR COMPANY

• 5.
  
  Disconnect the clutch master cylinder tube.

Courtesy of FORD MOTOR COMPANY

• 6.
  
  Detach the clutch master cylinder tube bracket from the master cylinder studs.

Courtesy of FORD MOTOR COMPANY

All vehicles 

• 7.
  
  Detach the battery cabel retainer.

Courtesy of FORD MOTOR COMPANY

• 8.
  
  Remove the 5 bolts, 4 nuts and the cowl extension.

  Torque:

  Bolts: 26 lb.ft (35 Nm)

  Nuts: 41 lb.ft (55 Nm)

Courtesy of FORD MOTOR COMPANY

• 9.
  
  

  • 1.
    
    Disconnect the brake fluid level sensor electrical connector.

  • 2.
    
    Detach the wiring harness retainer from the brake fluid reservoir.

Courtesy of FORD MOTOR COMPANY

• 10.
  
  Disconnect the 2 brake tubes at the HCU.

  Torque: 20 lb.ft (27.5 Nm)

Courtesy of FORD MOTOR COMPANY

• 11.
  
  Unclip the brake tubes.

Courtesy of FORD MOTOR COMPANY

• 12.
  
  Remove and discard the 2 master cylinder nuts. Remove the master cylinder and brake tubes.

  Torque: 17 lb.ft (23 Nm)

Courtesy of FORD MOTOR COMPANY

• 13.
  
  Disconnect the vacuum sensor electrical connector.

Courtesy of FORD MOTOR COMPANY

• 14.
  
  Detach and position aside the fuel pressure line from intake manifold clip.

Courtesy of FORD MOTOR COMPANY

• 15.
  
  
  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 stop lamp switch. Refer to: Stoplamp Switch .

• 16.
  
  
  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.

  Remove and discard the booster push rod clevis-locking pin and position aside the booster push rod.

Courtesy of FORD MOTOR COMPANY

• 17.
  
  Remove and discard the 4 nuts.

  Torque: 17 lb.ft (22.5 Nm)

Courtesy of FORD MOTOR COMPANY

• 18.
  
  Remove the brake booster.

Courtesy of FORD MOTOR COMPANY