Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT: Removal

NOTE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

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

NOTE: 5.0L 32V Ti-VCT engine shown, 5.2L 32V Ti-VCT similar.

All vehicles

Remove the cowl panel grill. Refer to: Cowl Panel Grille
Disconnect the battery cables. Refer to: Battery Disconnect and Connect
Detach the vacuum check valve from the booster and position aside.

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Vehicles equipped with manual transmission
Remove the brake fluid reservoir cap.

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

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Disconnect the clutch master cylinder tube.

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

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All vehicles
1. Detach the battery cable retainer.
2. Remove the nuts and the cross brace. Discard the nuts.
  Torque: 41 lb.ft (55 Nm)
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Remove the bolts and the cowl extension.
Torque: 26 lb.ft (35 Nm)

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Release the clamp, remove the pin type retainer and position the noise generator aside.

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1. Disconnect the brake fluid level sensor electrical connector.
2. Detach the wiring harness retainer from the brake fluid reservoir.
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Disconnect the 2 brake tubes at the HCU.
Torque: 30 lb.ft (40 Nm)

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Unclip the brake tubes.

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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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Disconnect the vacuum sensor electrical connector.

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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
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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Remove and discard the 4 nuts.
Torque: 17 lb.ft (23 Nm)

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Remove the brake booster.

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