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.

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Vehicles with manual transmission 

• 3.
  
  Remove the brake fluid reservoir cap.

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

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• 5.
  
  Disconnect the clutch master cylinder tube.

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

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All vehicles 

• 7.
  
  Detach the battery cable retainer.

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

  Torque:

  Bolts: 26 lb.ft (35 Nm)

  Nuts: 41 lb.ft (55 Nm)

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• 9.
  
  

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

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

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

  Torque: 20 lb.ft (27.5 Nm)

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• 11.
  
  Unclip the brake tubes.

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

  Torque: 17 lb.ft (23 Nm)

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• 13.
  
  Disconnect the vacuum sensor electrical connector.

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

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• 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.

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• 17.
  
  Remove and discard the 4 nuts.

  Torque: 17 lb.ft (22.5 Nm)

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• 18.
  
  Remove the brake booster.

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